00 BH crank sprocket replacement

[Grimmrican]

Sup my fellow sli-ers. Today I bring upon u a story and some questions.

Story:
My gf owns a 00 BH ej252. Now yesterday she left our driveway and drive about 1/4 mile down the road at around 25-30mph (construction site) and stopped at the gas station. She called me at work to tell me that her brake light and battery light has turned on. She also went ahead and told me she has no power steering. So I asked if there was a belt left on her car which she responded with an answer, no.

I told her to drive the car the best she could to my job and ill put a new belt. Within minutes she was at my job and another 3 minutes the new belt was on. Now as I looked down into the engine bay I saw the harmonic balancer/ crank pulley ( I don't want to get into a big tiff about wtf it's really called lol) and it was super wobbley and would explain what happened to the belt in the first place.

Here's some photos for those of u who hate reading and there's no pics.
The inside of the balancer/pulley
https://sl-i.net/FORUM/images/imported/2013/06/my3yjara-1.jpg

Next to a new balancer/pulley
https://sl-i.net/FORUM/images/imported/2013/06/udaty6u5-1.jpg

https://sl-i.net/FORUM/images/imported/2013/06/zu9a3avu-1.jpg

So my hypothesis was the woodruff key/ keyway/gatekey snapped somehow and destroyed the balancer/pulley that u see above. Upon a closer look. It took out the crank sprocket too

https://sl-i.net/FORUM/images/imported/2013/06/yzupa6ur-1.jpg

https://sl-i.net/FORUM/images/imported/2013/06/5eputupe-1.jpg

https://sl-i.net/FORUM/images/imported/2013/06/4evuhazy-1.jpg

So the question:

How in the fuck do I replace the sprocket??!!

[Garrison]

Undo the tensioners, remove the belt, and pry that mother off?

[harrymaneuvers]

viewtopic.php?f=11&t=19026 (https://sl-i.net/FORUM/viewtopic.php?f=11&t=19026)

I would bet that the crank bolt came loose somehow which allowed a little space in between the crank sprocket and the crank pulley... once there is enough room, the woodruff key slips out and starts coring out the inside diameter of the crank pulley.


You need to remove the timing belt and crank sprocket and see if the keyway in the crank is jacked up beyond repair or not. The woodruff key should fit EXACTLY in place... if it wobbles at all, your crank sprocket will be off timing by a degree or two.

[Grimmrican]

Well that would explain how it got damaged. Not torque to spec obviously. Thanks to the previous owner. Now I can get a NEW crankshaft sprocket for just under 50$. Perks of working at a parts store ~_^. So I'm planning on ripping that bitch out regardless. My question is after I do the tensioners and belt off how exactly do I take the sprocket off? Is it bolted on internally or externally?

[rkrenicki]

Yea, I would be worried about the keyway on the crankshaft too.. that is what I was talking about on the phone last night.

[Grimmrican]

Great. Something that I thought would just be a cheap and easy fix is turning to something huge n major. I can only pray it didn't damage the crank shaft

[rkrenicki]

I do not know about how it is attached, but I would be willing to bet that it is just put on there using the key to keep it from spinning, and the pully is just holding it on. From those pictures, it looks like at least the end part of the key galley is screwed up.

It looks to me like it is just wedged on there. There are two round holes on the sprocket, are they threaded? I would see if you could get some bolts in those and use a gear puller to back that off. I am going to go look in the FSM to see if I can get any more info on it.

Also, how is the car running? does it seem like the timing is off? I just wonder if the whole sprocket is twisted a few degrees on the crankshaft...


EDIT: So, I found the page of the 2000 FSM that talks about it. The step for removing the crank sprocket says "remove crankshaft sprocket" and shows no tools.. so, it must (normally) pull right off.

The page is here, page 16: http://jdmfsm.info/Auto/Japan/Subaru/Le ... L16120.pdf (http://jdmfsm.info/Auto/Japan/Subaru/Legacy%20Outback/2000/Service%20Manual/ENGINE%20SECTION/Engine/MSA5TCD00L16120.pdf)

[Grimmrican]

Thanx!! Ur a good man. I been talking to some of the gear heads an one guy told me he's done a bunch of them that they should slide rite out after the belt is removed. And I believe the holes are threaded so I could even use a small pulley puller or something of the sort. Now all I need is time :/

[Grimmrican]

Rkreniki Ty so effing much. I looked so hard last night for this and only kept finding the first page which I was beyond that. This should help me breeze (slight breeze mind u) with less swearing and flesh wounds lol

[harrymaneuvers]

If the sprocket hasnt been removed before, and especially because the woodruff key is damaged, it might be on the end of the crankshaft really good. I used a 3 jaw puller when I had to do this on the 01 Forester motor with like 130k miles on it.

If the keyway in the crank is damaged hopefully it is only on the side that the motor was rotating towards and the other side of the keyway is still straight. If so, I would be you could place a new woodruff key in the keyway flush against the good side and then spot weld on the other side followed by sanding/grinding to make it fit the original crank profile around the keyway.

If the crank is damaged on both sides of the keyway it is time for a motorswap or you are breaking the block open to replace the crank.

[Grimmrican]

Well lets hope for the best lol

[Dead91silvia]

If the car was still running, you should be ok. The key way is a critical part, yet it it can still work when damaged.

Use a bit of PB Blaster on the crank to help the pulley come off. I have only had a problem with them a couple times.

[Subafreak]

WTH? Is this the job Sandy was getting parts from me for?

[Grimmrican]

Yea!! But I didn't tell her to get the parts! I asked if she had any or could get any. Then the next day u came to my store at aap and I asked u if u had any lol

[Subafreak]

Yeah that's weird. She said they were for like Eddies dads car or something. So now I'm just confused. Lol.

[Grimmrican]

Eddie is my brother. And I think she was gonna grab something for my dads BG as well as the sprocket? For my BE.

[Subafreak]

Well I know I gave her all the parts that would be needed to fix what you need. For whoevers car it's going in. Lol.

[Grimmrican]

Well that's good to know thanx

[Grimmrican]

Ok so here's an update. I managed to put the cars timing to 0 and got the idler pulley off and the belt. Now I need a special tool to remove the damn crank sprocket?? I'm so damn close I can almost taste the win. But now I'm stuck and need help....

[Subafreak]

I'm guessing the sprocket is stuck on there pretty good? Time for a puller or some prybar action!

[Dead91silvia]

They can be a pain sometimes... Pry bar and a lot of penetrating oil are going to be your friend.

[Grimmrican]

Sorry here's another update: 2 days ago I got it out with 2 3' pry bars on the opposite side of each other. Took about 10 minutes to pry it off. Also had a friend help. It's great working with someone who can give u ideas when u have brain farts lol

[rkrenicki]

How does the crankshaft look?

[Grimmrican]

It looks like a crankshaft lol. I'll get a pic up when I get back home

[Grimmrican]

So today I order a "crank sprocket" from auto part international and ended getting one of the cogged gears for the timing. Then told the drier it was wrong and shipped it back with him. I got on the phone an spoke to the guy who sold me the part and argued with him for 45 minutes that I needed the crank sprocket that goes to the CENTER of the engine not the lower driver side. And eventually asked to speak to someone who has ever disassembled a subie engine. Finally a guy got on the phone and knew wtf I wanted and was talking about right off the rip. in the end I called up Secor Subaru here in CT and they can et me the correct part for 14$. I asked if he could send me a diagram thru fax which we were on the same page. So had him order one for me. I should have it by tuesday

[Grimmrican]

https://sl-i.net/FORUM/images/imported/2013/07/amudu5at-1.jpg

https://sl-i.net/FORUM/images/imported/2013/07/rysasy6e-1.jpg

[rkrenicki]

What about the keyway on the crank? you said it looked like a crankshaft, but is the keyway fubared up?

[Subafreak]

Yeah your definitely gonna need a new keyway also! Get back on the phone!

[Grimmrican]

Chill guys lol I bought the harmonic balancer a few weeks back which did come with the keyway so I'm all set lol.

[Subafreak]

It actually came with the keyway!? Sweet deal!

[harrymaneuvers]

Now that you have taken off the crank sprocket can you take a picture of the keyway at the end of the crank?

From your pictures with the crank sprocket still on the crank it looks like the keyway is messed up pretty bad.

The keyway should fit the woodruff key perfectly and if it doesnt, your crank sprocket will be slightly out of timing.

[Grimmrican]

Yea I will tomorrow after work. I been really busy these passed few days and haven't had any progress with the BH yet.

[rkrenicki]

Yea, I have not been asking about the woodruff key or the notch on the sprocket.. but the notch (keyway) on the crankshaft itself.

[Grimmrican]

I knew what u meant lol

[rkrenicki]

Well, you said it came with a new one, which confuses me as how would a new sprocket come with a new notch for your crankshaft?

[Grimmrican]

Ok u just confused the hell out of me. So.

The new balancer comes with a new woodruff the condition of the notch on the crank itself has to be filed just a bit so the new woodruff could sit in there nicely.

I called Secor Subaru yesterday to see if the part came in, and it did, so now I have to go get it Friday.

[harrymaneuvers]

Be VERY careful with filling/welding that new woodruff key in place.

You are going to want to make sure it is seated as far to the Drivers sided of the slot in the crank as possible as that side is most likely still true and not mangled.

You are also going to have to remove all weld/fill material above the surface of the crank or else the sprocket wont fit AND it might be out of balance.

How many miles on this car/motor? You might consider doing an oil pump while you are in there and using red locktite on the crank bolt and torquing that thing down to high hell.

[Grimmrican]

Yea the driver side of the slot seems unharmed. And believe me it's only going to be a spot weld I'm not gonna go crazy on the welding lol. Then try to file down where I spot weld it so its smooth so the sprocket and balancer can go in it with no problems. I've been getting great ideas not only from here but the guys at work too.

There's 160k all original except for the wp and timing belt. The oil pump seems to be in good shape. I'm just trying to get it running again so I can have my car back from my gf. If it breaks down again after its running she said she'll just sell it and get another one.

[Grimmrican]

So good news. I managed to get to Secor Subaru and get a new sprocket for 15$ after tax. The parts guy said these usually go for triple it's worth lol. Idc ill take it lol

https://sl-i.net/FORUM/images/imported/2013/07/usyrujan-1.jpg

https://sl-i.net/FORUM/images/imported/2013/07/ygu5a6ap-1.jpg

https://sl-i.net/FORUM/images/imported/2013/07/emabugeh-1.jpg

[Grimmrican]

So I attempted to put all the parts back together and right from the get go I noticed I wasn't going nowhere fast with the wrong woodruff key. The balancer I ordered came with the keyway and was the correct balancer but wrong key -__-

Here's the correct size on the left opposed to the incorrect size on the right

https://sl-i.net/FORUM/images/imported/2013/08/4emytaja-1.jpg

[Garrison]

What a rash of bad luck mate, that sucks :/

Do they expect you to cut your own or something?

[Grimmrican]

Meh shit happens. Idk what the hell was expected. But at least I'm closer to goal. Now I just need a dremmel

[rkrenicki]

The car is now back together. There is still a chunk of the crankshaft missing to the left of the keyway (if looking at the car from the front) but it is only on the front half.. The Woodruff key is wedged in there just fine with no movement at all. The hardest part was re-compressing the timing tensioner and the timing itself, but between the two of us, we got it running like a top.

[Grimmrican]

^wooot Bh running like a boss on thanx to ^^ rkreniki^^ between the 2 of us we have no experience with timing but we did figure it out lol. Thanx again bro. My gf is so ecstatic now def earned me some brownie points lol.

Complete:
https://sl-i.net/FORUM/images/imported/2013/08/za2yze3u-1.jpg

Ron putting the wrench work in:
https://sl-i.net/FORUM/images/imported/2013/08/y9y2ebu3-1.jpg

My bro in law showed up to do a tune up on his BG:
https://sl-i.net/FORUM/images/imported/2013/08/yjaryzug-1.jpg

My son taking lessons in his car seat lol:
https://sl-i.net/FORUM/images/imported/2013/08/eguvu7yb-1.jpg

Everything back together and running:
https://sl-i.net/FORUM/images/imported/2013/08/esuqemeg-1.jpg

[Grimmrican]

Hey guys n gals. Just a quick update on the BH and she's still running awesome with no problems whatsoever.... Well the engine is running awesome but there's an a electrical problem?

I took it for a ride yesterday and noticed that every time I hit the brakes the PRND light gets dim. I figured ok no big deal. But later the same day I was driving my BE and my gf was following me and when i looked back I noticed every time she hit the brakes the corner light would turn on! I pulled her over and made sure that was the problem and it definitely is. Every time u hit the brakes the PRND light dims and the front corner lights turn on. I'm baffled as to y as it never did that before the car sat.


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