Crankshaft timing gear removal - Defender Source
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  #1  
Old January 28th, 2012, 08:42 PM
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Crankshaft timing gear removal

I had the pleasure of removing my seized timing gear from the crankshaft today on my 300 tdi. I have the timing belt tool kit, but it did not include a crankshaft gear puller. I figured I post up how I did it in case anyone else runs into this issue.

The timing gear has 3 5mm bolt holes in it to attach a puller. If yours is seized you need to find some long 5mm bolts that are hardened. I had no such luck. I went to the dealership where I work to see if we had the puller, which we didn't. After running around looking for bolts I decided to take a different route. I ended up drilling out and tapping the 5mm holes to accept a .25" bolt that was part of a puller set I already had. Once I did this it came right off!

It is also worth noting that I had extra room to work with because of the 300tdi/lt77 combo.
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  #2  
Old January 28th, 2012, 09:19 PM
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Jason Lavender
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Are you doing the entire timing belt, timing cover seals, etc I'd assume?
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Old January 29th, 2012, 01:00 AM
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I'm doing the belt, three pulleys, and the cover gasket. I didnt order new crank seals, but they weren't leaking, so I'm not too concerned.

I'm going to reseal my vacuum pump too, if it will clear the inner fender.
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Old January 29th, 2012, 09:36 AM
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Mine was siezed on too. I used my clutch puller from a puch moped. Its cheap and works perfectly with a heavy washer. Also works for the steering wheel.

http://www.treatland.tv/puch-clutch-...puller-e50.htm
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Old January 29th, 2012, 07:52 PM
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Jimmy, you get everything done? Running?
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Old January 29th, 2012, 08:34 PM
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I did finally! I had trouble getting the belt on because I forgot to slacken the bolts on the injection pump, but that's what I get for not looking at the manual... Thanks again for letting me borrow the tool kit! I'll get in touch with you about returning it this weekend.
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