New Pulley, Fitting And Woodruff Key Question

Hey guys,

I removed my grill, and radiator and got the old bent crank pulley out. Cleaning up the TC and got my new seals, etc.

Here’s the question. The old pulley was snug, but came off by hand. I’ve got an identical stamped new pulley, but the groove is too tight for the woodruff key. I am test fitting first before getting my seals ready and such and the new pulley has to be gently tapped to seat it, and the woodruff key is cutting a very (very) small groove in the groove. Is this normal? I tapped it on a little, removed it, checked and filed the burrs in the groove, then repeated.

But now, My new rookie issue is that my pulley is stuck on the shaft. The TC is on the bench being cleaned and prepped. Going to get a puller and remove the pulley, but it is so tight on the key.

Any advice?

Thanks.

 

Slip it on without the key and use the backside of a dial caliper to measure the height of the keyway, swap to the other pulley and compare.. Compare that to your key and file/stone your key to fit..

 

Thank you.

I got a pulley puller and got it off, then started filing and prepping both the key and the pulley groove… and now the pulley is stuck again! I’ve damaged it beyond repairing trying to remove it. It’s still stuck on there.

I’m so frustrated right now.

Does anyone have any other removal techniques? My puller is at its limit. I’m tapping all around the pulley and trying everything. Maybe some heat on it?

thanks guys.

 

Cover is off. I’m attempting to “dry fit” the offending pulley before re-sealing everything. I’m thinking too that I need to get a torch and heat up the center of the pulley. It’s definitely stuck on the woodruff key, and will not seat. A few taps with a large socket and it’s like it’s welded to the crankshaft!

 

Using heat to overcome an interference fit seems like a mistake. Suspect you'd never get it apart again.

I would try honing the inside of the pulley first. As long as there is no radial sloppiness, and it all fits together, it should be fine. An abrasive hone sold for brake cylinder repair would be fine for that. I'd also polish the crank end with crocus cloth, to remove any roughness.

https://www.amazon.com/CTA-Tools-1140-8-Inch-Cylinder/dp/B003553F54?th=1

 

Pulley is off! 15 seconds with the torch (on the pulley slot area) and under tension with the puller… came right off. Finally!!!

Good points Timgr. Now I need to figure out how to fit a new pulley without having to beat it into place. The offending pulley slot was slightly narrower than the woodruff…

… lesson learned for this rookie.

 

Absolutely! Good advice!

 

Stick with it. It's how you end up with a great Jeep. Stuff like this is frustrating but part of the learning process.

 

If I could sell my experience for what it cost me, I'd be a wealthy man. But yeah.

 

Stumbles across this today
https://shop.midwestmilitary.com/product/water-pump-pulley-nos/
It will fit correctly.

 

Thanks but I think that’s the water pump pulley. But I appreciate the help.

I did get a new crank pulley and got it installed a while back, seems to be holding okay. The inside diameter of the replacement was also causing the pulley to bind on my crankshaft. Some light filing on the pulley allowed it to fit just right!

 

I have had to hone the inside of two new crankshaft pulleys I have used lately, and often have to use a stone on new woodruff keys for these or back axles. Like already mentioned I use a brake cylinder hone to polish the bore a little.