Crank pulley and timing belt crank gear "extraction" question

[rc000e]

Boy...American engineers sure know how to make sh*t rediculous and difficult. This clutch ...."why" is a one worded question that comes to mind. Anyway, I move on to the crank pulley. No woodruff key and this crank pulley is pressed on!? I break a pulley remover tool to get this thing off, now the crank gear doesn't budge for anything.

So now I'm in a bind. Is there some 420a "pro trick" to getting this thing off of here. Motors that make sense have the crank gears and pulley just slip right off...guess Dodge felt like adding labor hours to the repair books. I can't believe I'm fighting this motor

Any help on extracting this thing?

 

[99RedGs]

Boy...American engineers sure know how to make sh*t rediculous and difficult. This clutch ...."why" is a one worded question that comes to mind. Anyway, I move on to the crank pulley. No woodruff key and this crank pulley is pressed on!? I break a pulley remover tool to get this thing off, now the crank gear doesn't budge for anything.

So now I'm in a bind. Is there some 420a "pro trick" to getting this thing off of here. Motors that make sense have the crank gears and pulley just slip right off...guess Dodge felt like adding labor hours to the repair books. I can't believe I'm fighting this motor

Any help on extracting this thing?

I just used a 3 jaw puller and my impact wrench. It takes a long time to get it off. I removed the bolt and stuck a long 1/4 drive extension in the hole for the puller to push off of. Then I just kind of pulsed the impact wrench. When it moves at first it is hard to tell, but I bet you are moving it. Look from the top down at where the pulley nears the block and you should see what I mean. My puller was just one I rented from Checker. I think the best way to do it is just pulsing your wrench and maybe you need to turn down your psi if you were using an impact already. Also you may need to place a bar or wrench or something in the pulley to jam it so it doesn't turn while you are torquing on it. Thats all I got for ya man. They can be a bi***.

Heh, it was worse putting it on for me because at first I put a 5/8" extension in the whole to push off and bent the hell out of my threads in the crank so I couldn't use the bolt to pull the pulley on tight since it is pressed on. A 1/4" works fine though.

Good Luck

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This was my first experience with this pulley and I thought the center was a shaft that the pulley was pressed on to, but the center is part of the pulley and you can't even see the shaft that the pulley is on. I'm stupid I know, but maybe I'm not the only one who thought that their first time seeing that pulley. So If you were thinking that maybe you have moved the pulley and just don't realize it.

 

[cs82685]

So are you trying to get the crank pulley off or the crank sprocket off? You said both pulley and gear.

Anyways crank pulley, rent a 3 jaw 5 ton puller from autozone for chrysler applications. If you're now trying to get the sprocket off after you got the pulley off, then I used this type of puller...

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I drilled the holes out on the stock crank sprocket because finding long enough bolts that were so small was a pain and the sprocket is only about $13 from the dealer so I replaced it. Edit just a note, the crank sprocket does have a woodruff key, but the crank pulley is just pressed on.

 

[SurrealDSM]

to remove the crank pulley you need to get the crysler three jaw pulley and use the longer rod in the middle its extremely easy to take out with this tool you can rent it at any autozone but as for the sprocket thats a new one for me havent gotten to that removal yet

 

[rc000e]

Yeah...I got the crank pulley off after some time. I used my puller and my impact. The sprocket is the issue. That damn thing is stuck for good.

So, since this is pressed on, what the hell do you use to get the crank pulley back on and the timing marks aligned correctly?

Glad to know the sprocket is cheap, because I used a bearing extractor tool and the edges broke off of it. So, it looks like I'm gonna drill out and tap the holes in the sprocket so they can use the long bolts with my pulley puller kit.

 

[VelocitàPaola]

Yeah...I got the crank pulley off after some time. I used my puller and my impact. The sprocket is the issue. That damn thing is stuck for good.

So, since this is pressed on, what the hell do you use to get the crank pulley back on and the timing marks aligned correctly?

Glad to know the sprocket is cheap, because I used a bearing extractor tool and the edges broke off of it. So, it looks like I'm gonna drill out and tap the holes in the sprocket so they can use the long bolts with my pulley puller kit.

That's actually a little trick I'm finding many people are doing in order to make pulling the crank sprocket easier. You might consider drilling and tapping larger holes even on the new, replacement sprocket.

Chrysler makes a specific tool for installing crank sprockets, but you can easily improvise one. I don't remember the exact ID, but buy a piece of 6"x1-1/2" (I think) threaded steel piping with cap from Home Depot/Lowe's. The pipe should fit over the crank but obviously not over the sprocket/pulley.

Line up the sprocket over the key, then using the pipe, begin tapping on the capped end to push the sprocket on. There's probably some measurement to use to ensure the sprocket is pushed on enough, but you can eyeball it down to about 1/8" away from the oil pump. Repeat the procedure for the crank pulley for up to the first ~1/4" of the end of the crank. From there, you can use the crank bolt to pull the pulley the rest of the way. It'll also force the crank sprocket to be exactly where it's supposed to be.

 

[cs82685]

So, since this is pressed on, what the hell do you use to get the crank pulley back on and the timing marks aligned correctly?

Well the first time I was very careful and went the route of hunting down a longer than stock bolt that threaded into the crank to pull the pulley onto the end of the crank. Didn't want to hit it on because I was afraid of damaging the end of the crank. Next time I had to replace the sprocket and was told that you hit it on. So I said screw it and used a small sledge hammer and a socket to install both the sprocket and the crank pulley.

As for aligning the timing marks, the sprocket can only go on one way because of the woodruff key, just make sure the lip is facing out.

There's probably some measurement to use to ensure the sprocket is pushed on enough

There's actually is a tiny little lip on the crank so you shouldn't even be able to hit it on too far

 

[rc000e]

Got the sprocket off FINALLY. I actually broke two more pulley tools on this freakin junk. I used a tool like posted above by cs82685, and the threads of the center bolt that you turn on actually stripped off.

I had no choice but to cut a slit in the sprocket, then use an air hammer with a chisel to fracture the sprocket. It then split the sprocket and the tool was able to pull it off....what a stupid ass pain.

Motors apart now. The guy really wreaked havoc on it. He heard it tapping, but just revved on it and continued beating it. It spun several bearings. I think the crank can still be cut down, and the bores survived. The only issue is that the drop in oil pressure really did the head in, and there's alot of cam and cam bore damage in the head. I don't think the head is going to be salvageable unless they make oversized cams....

 

[mrj82]

Got the sprocket off FINALLY. I actually broke two more pulley tools on this freakin junk. I used a tool like posted above by cs82685, and the threads of the center bolt that you turn on actually stripped off.

I had no choice but to cut a slit in the sprocket, then use an air hammer with a chisel to fracture the sprocket. It then split the sprocket and the tool was able to pull it off....what a stupid ass pain.

Motors apart now. The guy really wreaked havoc on it. He heard it tapping, but just revved on it and continued beating it. It spun several bearings. I think the crank can still be cut down, and the bores survived. The only issue is that the drop in oil pressure really did the head in, and there's alot of cam and cam bore damage in the head. I don't think the head is going to be salvageable unless they make oversized cams....

There is another special tool puller for the crank timing gear btw. There are some companies that can fix your head, check out indy cylinder heads, or darrel cox racing.

 

[VelocitàPaola]

It's not worth fixing the head at all... they can be had for so little these days.

 

[mrj82]

It's not worth fixing the head at all... they can be had for so little these days.

Probably so.

 

[cs82685]

I had no choice but to cut a slit in the sprocket, then use an air hammer with a chisel to fracture the sprocket. It then split the sprocket and the tool was able to pull it off....what a stupid ass pain.

I forgot to mention that this is actually how some of the neon guys do it because they are so cheap to replace. At least you finally got it off

 

[Shadow98]

You could've just gone to AutoZone and borrowed the Chryster Harmanic Blancer remover...

 

[iknowless]

You could've just gone to AutoZone and borrowed the Chryster Harmanic Blancer remover...

New guy reviving old post. I tried the harmonic balancer remover, the bolt threads are so tiny they just broke off in the sprocket. I was going to try to rig up a tool of some fashion, but this air chisel intrigued me. How did you chisel off the sprocket without damaging the crankshaft?