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Old 13-07-16, 09:09 AM   #1
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Unhappy Keyway job, woodruff key stuck

Hey guys, I've been struggling lately with a worn out woodruff key eating up my sprocket

I ordered a new timing kit, (belt + pump), new woodruff key, new crank sprocket and pulley and a new front crank seal

removed all the damaged parts, but now i'm stuck at the dreaded woodruff key..

As you can see in the image, it's worn on one side, impossible to pull out with any kind of vice, it just slips and impossible to get a grip due to the smooth slant.

13699367_10155009289482306_2027850108_o.jpg

are there any tricks you guys know about ? i could surely hammer it out but as you see the sleeve from the oil pump gear on the inside is covering the inner half of the key so hammering won't help as it can't rotate freely in it's keyway

What should I do ? is my only choice now to remove the pump sprocket on the inside to get clearance and hammer it out ? please tell give me your wildest ideas, I don't want to remove that unless it's easier than it looks

thanks !: )
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Old 13-07-16, 03:22 PM   #2
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I would try to get something under its front edge to lift it out but it all depends how much of the inner gear is touching it it may not have enough clearance they are not usually very tight
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Old 13-07-16, 03:33 PM   #3
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I don't think that it is possible to get it out with the sprocket in place.You are not supposed to have that much gap.
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Old 13-07-16, 03:56 PM   #4
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They do sometimes come out that way it depends how much of the inner gear is in the way if its half way or less it will come out as the key is curved at bottom so simply rocks out.

looking at the pic i recon too much of it is under the gear though so as it comes up it will jam.
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Old 13-07-16, 04:42 PM   #5
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Quote:
Originally Posted by sva86sva View Post
I don't think that it is possible to get it out with the sprocket in place.You are not supposed to have that much gap.
I agree,that sprocket has to be removed.
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Old 13-07-16, 04:53 PM   #6
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Thanks a lot everyone!, that sucks, guess I'll have to bite the bullet and do it.

Here's what I imagine I'll be doing

1- remove the casing in front of the sprocket

2- release the tension from the chain / unlink it if it has no tensioner

3- pull out sprocket

4- tap out the woodruff key

After that I'll just do everything in reverse order

Do I have to worry about anything specific? Like oil leaking or anything in there that might need replacement while I'm in there?


Thanks a bunch for the feedback
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Old 13-07-16, 05:29 PM   #7
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Sadly it is a bit more complicated than that

The oil pump is bolted to the bottom of the block inside the sump and to release the chain you will need the pump unbolted this means removing the sump !
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Old 13-07-16, 06:25 PM   #8
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Quote:
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Sadly it is a bit more complicated than that

The oil pump is bolted to the bottom of the block inside the sump and to release the chain you will need the pump unbolted this means removing the sump !
I had a feeling about that , could it be possible to unlink the chain and put it back together when i'm done ? just thinking out loud
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Old 13-07-16, 07:15 PM   #9
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No its not recommended to weaken the chain by messing with it sump not too bad apart from the silly bolts they use
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Old 13-07-16, 07:19 PM   #10
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Fair enough, that makes sense actually.

One last question, the oil pump is not timed in any way right ? meaning no need to mark where the chain and position was for refitting
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