Rolled woodruff key - How common is this? - Off-Road Forums & Discussion Groups
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post #1 of (permalink) Old 01-19-2008, 06:10 AM Thread Starter
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Rolled woodruff key - How common is this?

The zuk has been running poorly lately. Thought I had a vaccum leak because I had cracked one of the adapter plates for the Weber. Got new adapter plates and put it back together. Still ran like crap. Adjusted valve lash and checked fuel filter. Still crap.
Checked timing. The flywheel showed 10, but on the lower pulley it was more like 20 or more.
This is the second engine in this suzuki that has had that happen to.
Gonna have to take the front end apart and do some JB weld magic.

How many folks have had this happen to them?

Gene

88 stock tintop with Walmart hub caps - high falootin'
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post #2 of (permalink) Old 01-19-2008, 09:21 AM
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woodruff key wallowing...

Gene:

Unfortunately, this is a common problem - but not because of any design flaw.

From what I can tell, the woodruff key gets wallowed because someone decides to remove the crankshaft accessory pulley by removing the big bolt that holds the crankshaft timing belt pulley instead of the four (or five in the case of the 1.6 liter engine) smaller bolts that attach the accessory pulley to the crankshaft timing belt pulley. The accessory pulley must be removed in order to remove the timing belt cover.

When this bolt is removed, several things can happen.

1 it can be broken. If the broken end is not carefully removed, the replacement bolt (or worse - the reused original bolt) may not properly be tightened down to the required torque value with Locktite applied to the threads. This causes the bolt to work loose and the woodruff key to wallow.

2. If it is not properly torqued down and locktite is not used on the threads, it will work loose and cause the woodruff key to wallow.

Removing the accessory pulley using the four (or five) bolts that hold it in place is the factory-specified method to remove the timing belt cover.

Sometimes a shortcut will cause more problems than it will fix...

Hope that this helps!

Ack
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Last edited by ackerdackerly; 01-19-2008 at 09:23 AM.
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post #3 of (permalink) Old 01-22-2008, 01:19 AM Thread Starter
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Ack,
That is exactly what I found. When I got to the lower pulley, I was able to turn the bolt with my fingers. No locktite at all. The 4 small bolts had locktite on them. It was wallowed so bad that it took an hour of mechanical persuasion to get it off.

I rebuilt the keyways and the key with JB weld, then JB welded it to the shaft and drilled a hole (half in the pulley/half in the shaft) and cut the drill bit in place to act as another key.

I bought the motor about a year and a half ago and I thought the guy was good enough to think about stuff like this.

Thanks for the info and insight.

Gene

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post #4 of (permalink) Old 01-22-2008, 04:00 PM
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woodruff key...

by the way, I bought my '93 4-door JLX with 83k on it in that condition for $500. $1500 later I had a rebuilt engine with a remanufactured crankshaft. She still drives great!

Ack
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'88 "SJ-416 Samurai"
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