did it start to compress that washer yet? I wouldn't be too worried unless your tight against the crank and its still spinning. I would also suspect the pulley wasn't flush against the crank and the bolt is drawing it down.
I don't really know how to tell if the washer was compressed or not. I went back out and the cycle happened again (some resistance gone, then hard to pull again). Fortunately the tension got to the point where I was having to work very hard, but my torque wench still hasn't tripped....
That does not sound good.
Can you use a longer bolt to engage more threads?
Preload is everything. If the bolt does not holed the pulley on with enough tension it will try and move on the crank. This beats up the key and will loosen the bolt.
When a fastener has enough preload the friction forces on the pulley will always be higher than the engines vibration forces.
Try and use a longer shank bolt. I know that might mean going to an early design. I don't think these problems are so much a bolt problem as they are a preload problem. As long as you can get the bolt to the new torque level you will be fine.
Also loctite will change the friction of the bolt and affect the preload level. Do the torque instruction specify lightly oiled threads on the bolt?
Kevin
Kevin, that's my concern too. Longer bolt... well there is only an additional 8mm at the back of the hole and all the bolts I can find are 50 (like the OEM bolt) or 60mm. Yes I could grind it down a bit, but then there is the fact that it is an M14 with a fine thread and nobody has an M14, grade 8, with a fine thread. I looked everywhere. At this point I am willing to bet that I am not over 110ft-lbs, but I am afraid to try to go higher. Some say use a Helicoil or two, others say I can't, it would be a bad idea. I need it done like today, but man, what a terrible set of circumstances.
