Join Date: Feb 2001
Location: Kansas City, MO
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woodruff key wallowing...
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!
searchable links to Suzuki/Geo modding and maintenence info - including the Tracker FSM Project!
'88 "SJ-416 Samurai"
'11 Ford Transit Connect XLT
Last edited by ackerdackerly; 01-19-2008 at 09:23 AM.