a.n.other

Hi,

I'm trying to do a front end reseal on the 944 and the crankshaft woodruff key is causing me a great deal of bother - so much so, I'm having thoughts that it is welded on. I've got the smaller, square ended ones out of the balance shafts easily, but this larger, round ended one on the crank is proving more difficult. Does anyone have any golden tips to help me out?
Also PET shows there are a number of different sizes - why?

Also, where is the best place to get a cheesehead bit for the cam gear? - my rubbish Lisle one is stripped, so I figure I ought to splash out and get a decent one, or else drill it off.

Hopefully someone will help me get my car and associated bits out of my friends garage!!

Granite 944

I've always used a pair of bevel side cutters (wire cutters), grab ahold of front of key with cutters down against the crank flat, squeeze the cutters, and pry the key upward. Always worked for me. Clean up the key with a flat file, or better yet replace it. All these keys are half moon "woodruff" keys. Good luck!

shmucklebuckle

Get the tripple square bit from Snap-on, here.

FletchDM

Just to be clear, the woodruff key on the crankshaft is NOT a half-moon type. Perhaps that, technically, makes it something other than a woodruff key. Anyway, tapping on one end will generally not make it come out, as it would with the crescent-shaped woodruff keys on the balance shafts. Side cutters, vice grips, channel locks, etc. are the tools to try.

Good luck, mine was stuck too...
-David

a.n.other

So is the crankshaft a square edged key kind so like it could go in upside as easy as the right way up? And do you have to pull on it straight up with side cutters/vice grips to get it out? I'm just trying to get a picture of what it looks like. I may buy another one from the dealer just to see what I'm battling with.

Thanks for the Snap-On link shmucklebuckle - but what stores can you actually buy snap-on (in a hurry!)?

Thanks for all the useful info!

fezz

the key can be stubborn.
tap on the front of it with a wood chisel to pop the front out.
the taper on the chisel blade will direct the force up on an angle and lift the key.

Granite 944

OOPPS! Your right Dave. The crankshaft key IS a straight cut key. My mistake, I don't know where I got that.

Side cutters is still the thing I use. Using a chisel, I'll almost always damage the key more, getting it out.

fezz

always a good idea to have new keys on hand for both balance shafts, cam shaft and crank.

Dave951M

If you are gentle with the chisel, it won't damage the key any more than a little filing would fix. The side cutter thing works too. It helps to soak the area with PB Blast for a while before you start. If you have a replacement, then all the better.

Zero10

I usually use a sharp screwdriver hammered into the front edge of it, tends to lift it out very effectively.
I've had one stuck so badly that side cutters wouldn't take it out, the screwdriver took it out.

Dave951M

Same principle as a wood chisel. One tip here, when you have to use force of any type to get the key out, you might leave a small burr on the crank nose. Be sure to check for any rough spots before sliding the new seal back on the crank. If you don't and there is a burr, you'll nick your new seal and will develop a leak in short order.

RedlineMan

Indeed;

I have had them stuck as well. The keyway in the crank is FLAT bottomed, not round like the balance shafts. I've used a very sharp chisel tapped into the vertical leading edge of the key to create a small notch that can be used for leverage. If you are careful it will work out just fine. If you mark the key up a bit, you can simply dress any burrs down with a file.

ibkevin

Side cutter has always worked for me. Get a bite in the back third of the jaw and leverage the handles down using the front of the crank as your piviot. Because you are biting both sides there is less of a tendency to butt the key into the back of the flat keyway.

F18Rep

Some pretty smart guys around here...;] Bruce

timo944

I had to take a hack saw and cut a groove in the front of the key, only about 1/16" deep. Then I could get in there with a small hammer and a screwdriver and pop it up.

Buy yourself a couple - they're cheap!