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[Brachunky]

Eyup folks, cant seem to see an intro place so hello all! Had a few cherrys the last few years and now (after a lr spell ) am back with a 97 2.5td.Looking forward to getting on the lanes with it up here in Derbyshire
As per usual, one often seeks out a forum when yer in the poo and after plenty googling,I thought Id better ask!
Crank pulley did not turn with engine running so removed the pulley to see that the woodruff key had mangled itself up.I have half of the key removed from the crankshaft but a bit which seems to be stuck in the groove. Cant see too well whether the crankshaft sprocket has a key way too which may explain the stubbornness to come out? Any tips lads as I dont really want to remove the whole timing cover!!!

[Nosebolt]

there will be a keyway on both components, a picture may help explain your problem though as not exactly sure what your asking

[Brachunky]

Good idea! Here's a couple of close ups of the remaining bit of metal in the keyway!

[Brachunky]

Got it out in the end! Small bit,loads o trouble :icon_winkle:Was expecting the key to be half round but its a strange shape so guess it will be a genuine part.

[Dave The Sparky]

Looks like a normal key way to me on the photo.
If so you could measure the width of the slot and a local engineers suppliers will sell you a length of key steel.
Then all you got to do is get busy with the hacksaw and a file and you can have a go at making your own.

It looks like that gear is going to have to come off to the shaft to make it fit whether you buy or make a key anyway.

[MOCAJ]

 

I would however check the gear, it looks stretched in the above photo, look at the gap around the shaft and gear. There is a gap near the key but is tight elsewhere, you may need a new gear !

[Bubba]

I agree but at first thought it was my eyes

[Brachunky]

Thanks guys for the insight! Spent some time removing the necesary bits to get the timing cover off so that I can get the replacement key in place.All the timing cover torx bolts are out but before I try prise the cover off, Im unsure about two pins or are they locating studs which come through the cover. They look like a bolt without a head which makes me think they are a locating peg but im scared to try remove the cover in case I damage it! Sorry foe waffling

[Brachunky]

How is this sprocket removed and/or is it feasable to cut the woodruff key in half to insert which would leave the sprocket in situ? Would the key still do its job in respect of the crankshaft pulley?
I bow to your superior knowledge on this

[The Smiths]

best is to fit a full one, if you do split for ease make sure the join is in the middle of a gear - rather than on the join between

[Brachunky]

Thats a good point Mick, have you ever had the crankshaft sprocket off on one of yours?

[The Smiths]

Thats a good point Mick, have you ever had the crankshaft sprocket off on one of yours?

No - Luckily never had to strip one - at that end anyway

[daggie]

Put a full one back in,
time  the engine up.
Remove oil pump, bottom gear, then the vacuum pump the one above the crank gear.
the pics upside down though 

[daggie]

oh its not now 
hope this helps

[Brachunky]

Big help! Cheers daggie