I've tried the following:

-Tapping it with a flat screwdriver and hammer (lightly).
-Using a screwdriver as a chisel and tapping up while laying on the ground.
-All sorts of pliers, channel locks, angle cutters, etc.
-Lube
-Heat with torch and tried the channel locks, etc. again.

But I STILL CAN'T remove the woodruff key from the crank. What do you guys do?

I was thinking of using a Dremel tool to cut a groove along both sides to provide a better grip for end cutters. What do you think?

Drill it out piece by piece? I can't put my motor back together unless this is resolved, so any help is appreciated.

 

Get some end cutter pliers, they will do the trick nicely. They allow you to grab on securely and put even pressure on the key. I wasn't a believer until I was shown... they are the proper tool for this job.

Regards,

 

This key has a flat bottom. So you can't poke it like the cam or balance-shaft keys and expect it to swivel out. It has to be removed by pulling directly perpendicular to the crank. Spray PB-blaster on and let sit over night. Then grab with end-cutter pliers or vise-grips and pull straight out.

 

I had the same problem two weeks ago when i did my belts and seals for the first time. When i ordered the parts i ordered extra keys since they only cost $1 each and I started chewing some up when I tried using pliers and vise grips. I did a lot of PB Blaster on them and waiting. Only one was a problem. I took a short piece of hacksaw blade and cut into the front side of the key perpindicular with the crank. I could then get a short screwdriver blade in the groove i made and pry the key out. It took a couple of tries but it worked. Took a nice gulp of cold Corona in my garage after that sucker came out.

 

I clamped a small vice grips on the key, then tapped it out (lightly) with a small hammer. I tapped away from the crank, that key was really in there but came out pretty easily.

Arne.

 

I use a small, very sharp pair of dykes to bite the front of the key and then lever it straight upwards, this has never failed in 11 years of working on these cars. Mark T.