Crank shaft pulley

James · Mar 9, 2009

My Crank chaft pulley is a bit wobbley when I grab it and move it. What could the be, I get the feeling it is going to be a big job!

Paul D · Mar 9, 2009

Depends on the Disco ... I think D2 and TD5 have a composite pulley with rubber parts to it that can perish.

Otherwise take it off and see???

James · Mar 9, 2009

Sorry 200tdi,

I assume that if it was serious there would be oil leaking out from behind.

Tig9619 · Mar 9, 2009

sounds like the four bolts have come loose! not what you want really!

James · Mar 9, 2009

I have just had a nother quick look, the 4 bolts are tight I cant move the large bolt with my fingers but the deep spacer/washer behind that is loose and the section that the pulley bolts too is loose too, all as one piece. I can turn it as well about 1/16th of a rotation leaving the bolt inplace not spinning.

James · Mar 9, 2009

Oh and it does look like there may be a small leak from the cambelt housing drain hole.

CharlesY · Mar 9, 2009

James said:
I have just had a nother quick look, the 4 bolts are tight I cant move the large bolt with my fingers but the deep spacer/washer behind that is loose and the section that the pulley bolts too is loose too, all as one piece. I can turn it as well about 1/16th of a rotation leaving the bolt inplace not spinning.

Looks like the crankshaft pulley is loose on the nose of the crankshaft, and if it is it will soon batter the Woodruff key to bits and spin on the shaft. The shaft will be damaged in the process, and this event will cause you lots of grief.

I suggest you MUST get the pulley off soon and sort the keyway in the shaft, the slot in the pulley, fit a new Woodruff key (you may need to make one a bit oversize) and then bolt the thing back on REALLY TIGHT like the book says.

CharlesY

James · Mar 9, 2009

It may well have already damaged it I guess, how would I get out of the worse situation?

CharlesY · Mar 9, 2009

James said:
It may well have already damaged it I guess, how would I get out of the worse situation?

First take the pulley off and have a look.

You may want to check the cambelt driver pulley too in case it has moved forward and eaten the side of the belt.

Once the pulley is off you need to work out a way to get it back on WITH A BIG STRONG DRIVE KEY. If the Woodruff key slot in the nose of the shaft is mangled you may be able to forge it back to shape by careful biffing using suitable engineers' hammers. I have seen (and have done it myself) a shaft fixed by using a side grinder and cutting disk to slot the crankshaft to create a long keyway right to the end of the shaft nose, into which was tapped a length of 6 inch nail that had been hammered to the square section needed. Desperate jobs need desperate measures!

Once you have a plan, do it, and make sure the pulley bolt is as Goddam tight as it is supposed to be.

CharlesY

James · Mar 10, 2009

I am going to look in a weeks time when I am back, ( I am not driving it this week any way) it is due a cam belt change as well so I will go ahead and look at all of it.

I assume that if the shaft is knackered then it would be a case of taking the engine apart and replacing the part.

CharlesY · Mar 10, 2009

James said:
I am going to look in a weeks time when I am back, ( I am not driving it this week any way) it is due a cam belt change as well so I will go ahead and look at all of it.

I assume that if the shaft is knackered then it would be a case of taking the engine apart and replacing the part.

Shaft will NOT be knackered, and there are ways to effect a good fix without taking it out of the engine.

Don't damage it any more, and remember what is happening here.
The cambelt pulley and the crankshaft pulley MUST run straight and true, and they MUST be set up dead in line with the keyway for the Woodruff key so the cam timing will be good, and so there's a good strong drive for the crankshaft pulley.

LandRover arranged that situation one way using a modest size Woodruff key, and they arranged it that way because it suited them in the factory making the engines. But that's not to say that's the only way it can be made to work. A long slotted keyway on the shaft and a long square section (rectangular actually) key will be just dandy too. The pulley bolt will prevent it from falling out.

Careful engineering will see you through, and I mean CAREFUL.

CharlesY

James · Mar 10, 2009

Thanks Charles, I will let you know how I get on next week when I take it apart, and post some pics too.

CharlesY · Mar 10, 2009

James said:
Thanks Charles, I will let you know how I get on next week when I take it apart, and post some pics too.

yes please .... pics would be good, but I am pretty sure you will be able to repair the problem on the crankshaft .

There are TWO Woodruff keys of course, one for the cam-belt driver pulley, and one for the main front pulley. Hopefully the inner one will be fine.

Piccies ...

CharlesY

James · Mar 10, 2009

i will try and get some good ones

Dave 2000 · Mar 12, 2009

Check the archives, I did this repair on my 200tdi and posted a few pis ect, the keyway in the crank was busted up but as charlesy said, get a couple of new keys and do the bolt up seriously tight. FWIW I bought a new bolt/washer/crank pulley.

regards

Dave

dansoliver · Mar 13, 2009

I had this with my 200 disco, some idiot hadn't done the bolt tight enough and it broke the key fully.

in the end i replaced the timing pully aswell had to make an adaptor and use a 10ton puller to get it off. this is what it looked like to start with though.

James · Mar 19, 2009

just working on it now, looks like the damper has fractured at the key way, it has worn down the woodroof key on the shaft and a section of the shaft has been worn out wider, what do you think?

CharlesY · Mar 19, 2009

James said:
just working on it now, looks like the damper has fractured at the key way, it has worn down the Woodruff key on the shaft and a section of the shaft has been worn out wider, what do you think?

Personally, I think that looks GREAT!!

Get the sheared-off bits of the key out, and see what damage has been done. It will probably be less bad than you think, and easy to fix. You may well be able to tap down the edges of the wear area by careful use of the ball end of a one-pound ball-pein hammer, but even that may not be necessary. Try NOT to file metal off - pein it back to shape if at all possible.

Good job so far!

CHarlesY

James · Mar 19, 2009

Well I had to decide what to do, the damper is cracked at the end where the woodruff key sat, and the shaft keyway had been worn twice as wide at that point, b removing the remining key would have left me with a crator.

So rightly or wrongly I have cut a new keyway in the end off the shaft and made a key to fit both sides. I have fitted it all back together and all seems well.

Sorry the pic's are rubbish. I only had my phone with me.

CharlesY · Mar 19, 2009

James said:
Well I had to decide what to do, the damper is cracked at the end where the woodruff key sat, and the shaft keyway had been worn twice as wide at that point, b removing the remining key would have left me with a crator.

So rightly or wrongly I have cut a new keyway in the end off the shaft and made a key to fit both sides. I have fitted it all back together and all seems well.

Sorry the pic's are rubbish. I only had my phone with me.

That, Sir, is called ENGINEERING!

Be sure the pulley bolt is tight.

Good job,

CharlesY

Crank shaft pulley

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Old, nackered 'n broke, but the Landy is fine . :)

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