Weird problem...need help!

[94SubieSVX]

I finally got a chance to take the pulley off, it doesn't look normal. The back of the pulley looks like it is "shaved" down(i don't know the right word to use). and the key way (i guess thats it) on the pulley is chipped up a bit so it doesn't seem that it's making a good contact between the two. Also, the notch on the gear under the timing belt cover is a little bent. I'm trying to upload some pics but dial-up isn't the best for hi-res images...it takes forr evveeeerrrrrrr




also forgot to add the pulley wore down part of the timing belt cover

[svxfiles]

Originally Posted by 94SubieSVX

Also, the notch on the gear under the timing belt cover is a little bent.

Can you explain this part a little better?
Thanks.

[94SubieSVX]

It's the notch thats right in-line with the 20 degree mark on the timing belt cover. the notch, and the area around the notch is banged up and looks worn.



It looks like its a notch to keep the pulley from spinning by itself. I don't think the pulley is sitting flat on that and that may be the reason it comes loose all the time.

[Budfreak]

Get a fresh pulley that isn't chewed up, Fix the woodruff key(the notch on the gear you were speaking of) if it needs fixed, and use a little red threadlocker on the bolt. Use a breaker bar and hammer to act like an impact wrench on the bolt by striking the bar with the hammer once you have the bolt snugged up as far as it will go without turning the engine. Also, Make sure the pulley is on the key before you tighten the bolt. You'll know it's on when you can't turn the pulley by hand in either direction. Good luck, And if you need any parts just let me know as I have woodruff keys and pulleys.

[94SubieSVX]

i checked out the woodruff key and it looks a little banged up so i might as well get a new/better one. Also the area it sits in looks like it loosened up and the woodruff key could move back and forth. Is that part of the crankshaft gear?

[svxfiles]

Thats a pretty crappy picture.

But if the groove in the crankshaft looks ok,
and both the sprocket and key have excess play,
then they need replaced.
Have you removed the crankshaft sprocket?
Tom

[94SubieSVX]

No i haven't taken the sprocket out yet. The area with the arrow pointing at(to the left of the woodruff key) is the area that looks worn. I guess it's part of the groove in the crankshaft? If i were to take the sprocket out would i need to take the timing belt cover off too?

[Budfreak]

Originally Posted by 94SubieSVX

No i haven't taken the sprocket out yet. The area with the arrow pointing at(to the left of the woodruff key) is the area that looks worn. I guess it's part of the groove in the crankshaft? If i were to take the sprocket out would i need to take the timing belt cover off too?

Yep, The timing belt cover will have to come off to remove the sprocket. Yes, That looks like the keyway in the crank took a little beating. Mine was much worse when it happened to me, But I got a new woodruff key and filled the area around it with some 2 step epoxy, Slapped on an underdrive pulley, and bolted it down in the previously described method with no problems since. Your sprocket also looks like it might be twisted a little. If it is, a new replacement is pretty cheap.

[94SubieSVX]

If it is, a new replacement is pretty cheap.

About how much?

[Budfreak]

Originally Posted by 94SubieSVX

About how much?

PM being sent.

[94SubieSVX]

got it

[94SubieSVX]

I just ordered stock size lightweight pulley from Motorsport wharehouse, next i gotta order the woodruff key from someplace

[svxfiles]

Originally Posted by 94SubieSVX

I just ordered stock size lightweight pulley from Motorsport wharehouse, next i gotta order the woodruff key from someplace

They are like $2.32 from Subaru.
http://www.subaruparts.com/cart/?pn=804505060
Part #804505060

[94SubieSVX]

Thanks for the link, I had tried 1stsubaruparts.com but had no luck.

[94SubieSVX]

Got my pulley from Dayle today. Also got a new woodruf key and timing belt cover seals(might as well while im down there). I just don't know how to take the old woodruff key out. Do i just loosen the crank sprocket and it comes out?