If I could get a hand on who ever worked on this engine before me I would send them to their maker with my hands wrapped around their neck. <img src="/forums/images/graemlins/angry.gif" alt="" /> <img src="/forums/images/graemlins/scared.gif" alt="" />

I just got the crank shaft bolt out, the factory tool works rather well btw. The lip on the crankshaft pulley is cracked away on two places.



Obviously the idiots who worked on this engine before me tried to use a puller of some sort to get the pulley off. <img src="/forums/images/graemlins/frown.gif" alt="" />

It is also dented in a couple of spots. Not enough to hit the belt but it isn't true. I am pretty sure if I try to bent them back they will snap off.

Does any one think I can smooth this out with a file and just run it.

I really don't have another 175 dollars to drop on a new pulley. I will if I have to, but this job is bankrupting me financially.

This isn't the only screw up that I have found. The timing belt cover was held on by oil pan bolts. I can only hope it was from another oil pan. There are bolts missing from the plenum that normally hold the vacuum lines and other things in place.

I am beginning to regret I purchased this truck. <img src="/forums/images/graemlins/rolleyes.gif" alt="" />

If that's the worst spot, I think you can round over the ragged inner edge of the break and run it for a while. You might have a slight engine vibration from balance issues. If you can afford the new one, it's a much better idea, though. Maybe a good used one can be found - should be $50-100. A new one is $130 at rockauto (I think you have a '95 3.5L)

Frank

thatl be fine for now.

I'd keep it in the back of my mind though.

Do you have a pic of the tool? Are you talking about one that holds the pulley in place while taking the bolt out? I want to see the tool. DougB loaned me a tool a while back but it did not work on my pulley I have seen one or two other people on this forum it would not work for as well.

I will take a picture of it later for you Tag.

Thanks for the response Curtis and Frank. I will file the rough edges smooth so there aren't any more stress risers. That is what I wanted to do for now, but I just wanted some reassurance. <img src="/forums/images/graemlins/scared.gif" alt="" />

If it vibrates too much I can always replace it down the road.

Time is more of an issue right now than cost.

Use a Dremel with a grindstone bit if you have one - it'll be easier and probably better than a file. A fine rat tail file will work, though.

Frank

I second the dremel, I use the sanding rolls and make it smooth. Someone had done this in four spots on the 3.5 I've got. I have 80,000+ miles with no troubles yet.

Doug: I dont want to be a spoil sport here. But my experience with pulleys like that, is they tend to tear up the belt. Especially if there is any misalignment which causes edge loading. I would replace the pulley and be done with it.
Conner

I think you want to be a spoil sport!!!! <img src="/forums/images/graemlins/lol.gif" alt="" />

Seriously; Look at the wear marks on the pulley, the belt has never even touched the outer edge, the paint to both sides of the break is untouched as it is along the entire outer edge.

A grooved belt wont move far enough over from its grooves to touch that outer edge / break. Dressing the sharp edge is not even needed, the belt wont ever touch it.

IF the belt moves that far out of its groove you have another problem such as you wrapped the front end around a tree.

Yes its ugly but as long as the pulley is not bent it will function.

Kevin

No Kevin, i gave my opinion based on what i have personally experienced. If you disagree with that, so be it. But you might want to have another look at that photo.
Regards
Conner