Removing crank gear 300tdi - Defender Source
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  #1  
Old October 30th, 2010, 10:21 PM
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steve
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Removing crank gear 300tdi

I need some advice. I'm mid timing belt change and I cannot get the crank gear off. I cant get it to budge at all. this is day 2 of trying to get the gear off.

-I have tried a variety of pullers that just mangled the gear.
-I made a puller that used the three M5 studs but I keep breaking the bolts.
-I tried light heat...nada

What else is there? Any pointers would be much appreciated.
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  #2  
Old October 31st, 2010, 07:29 PM
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Skinny Pete
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I would try perhaps a bit more heat, and/or attach the puller with hardened bolts and just get it under tension but not so much as to break anything. Then hit the gear with a big brass drift or something to set up some vibes. That might be enough to get it moving. try some PB blaster as well. Though it may be a bit tilted rather than really seized.


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Originally Posted by D90user View Post
I need some advice. I'm mid timing belt change and I cannot get the crank gear off. I cant get it to budge at all. this is day 2 of trying to get the gear off.

-I have tried a variety of pullers that just mangled the gear.
-I made a puller that used the three M5 studs but I keep breaking the bolts.
-I tried light heat...nada

What else is there? Any pointers would be much appreciated.
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  #3  
Old November 1st, 2010, 05:26 PM
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steve
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I did not think about it getting wedged, I'll tap it back and give it another pull with new bolts.

Thing is that it is not budging at all, there is a nice crust around the shaft, I scraped it off so I can tell there has been zero movement.

Is there anything I should be concerned about with heat besides melting the aluminum casing?
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  #4  
Old November 1st, 2010, 06:32 PM
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Doug Crowther
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I have had luck with getting things hot as the hinges of hell, loading the puller with plenty of tension and then spraying pb blaster, it smokes and burns off and I keep spraying then a good smack or 5 with a dead blow
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  #5  
Old November 1st, 2010, 07:47 PM
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Tony Lawson
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hey Steve -
for bolts that have more strength, go to sockethead caps. IIRC, the black alloy metric will be 12.9 hardness, which is beyond the metric 'grade 8' strength of roughly 10.9.
There maybe some at the local hardware here that has a pretty big selection of metric stuff if you can't find them.

then heat and hammer time

this is the crank gear, not the pulley, right? Can't see how that could get cocked if it's all the way on the shaft in the home position. have you removed the pulley key so it can't rotate up and wedge the gear as it comes off? (although it doesn't sound like it's even moved that far yet)

let me know if you need a big torch
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  #6  
Old November 1st, 2010, 09:36 PM
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kevin
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Have you tried an impact gun with the puller?
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  #7  
Old November 2nd, 2010, 12:09 AM
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steve
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I got it...
I had to go to a specialty fastener shop to get some long m5 bolts, the black allen ones. Those with the puller, and a lot of heat got it off.

I dont think it had ever been off.

cheers!
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