Can you replace the crankshaft key way on a 1996 Subaru legacy?

Answer 1

I have had 2 Subaru wagons that damaged the keyway when the outer pulley spun free. I figured out a way to fix it. First, only the outer part of the keyway on the crankshaft was damaged. The inner timing belt sprocket was still locked on to the crankshaft. Pull the sprocket off and take it with the pulley to a machine shop. There are two holes in the crankshaft sprocket. Have the machine shop drill (after lining it up with the pulley) through the two holes -through the pulley. Then have him install (you supply) two expansion pins(like the ones holding the inner part of the cv joint to the transmission. They come in different sizes-get one that will squeeze through when compressed. They(when compressed and inserted) will hold the sprocket to the pulley. They will lock on the crankshaft using the inner part of the keyway. When installing you will need to cut the timing cover in half (center section only)-also the lips around the circular part of the cover. The outer part of the keyway you can fix before install by coating a new key with vasoline and putting it in the slot. Then mix liquid weld and fill the damaged section. When dry the key should come out with a little help- tap. It should be free from adhesion due to the vasoline. Smooth the liquid weld to the shape of the crankshaft before it hardens. If you do it right-it will work. Both of mine work fine.