Daniel5691

So I don't know if I'm looking for advice or if I just need to rant.

1981 928S Euro ROW 5 spd.

Following Douglas Brownridge's excellent write-up on TB/WP as I hunt down this oil leak of mine.

AC Crankshaft pulley will not move. I have read all related threads I could find.
It does not "wiggle" at all.
Not in any direction, regardless of hand position.
I have spent a total of 4 1/2 hours of the past 3 evenings wiggling the pulley.
It has soaked each night in PB Blaster applied directly at the surface with a hypodermic needle.
Tapping with rubber mallet. Wiggle and Tap. ad nauseum.
There has never been even for the slightest moment any appreciable wiggle or movement.
I resorted to a bar-type puller, but noted that the outer rim of the pulley was beginning to deform and there was no motion at the crank at all.

So, I thank you for listening to me. We now return you to your regularly scheduled program already in progress.

Dan

dr bob

Bolt is out, and the washer (with the step towards the crank nose) is also off already? Shop 928 Int'l for a used replacement pulley.

There's nothing indexing the pulley to the crank nose. It's all friction and clamping. You might wrap the belt around the pulley, and around a socket attached to a handy breaker bar. The one you used to pull the crank bolt is a candidate. Put tension on the belt so that winding it around the socket and turning said socket with said bar tightens said belt on said other pieces. The belt will minimize damageto the pulley as you pull on the bar and rotate the pulley on the crank nose. Once it moves a little, the rest of the way will be easy.

Those pulleys sometimes get friction-welded in place when the stepped washer is put on backwards or the crank bolt isn't tight enough.

Daniel5691

Hi Doc,
Yes sir, bolt and washer out away in the ziploc bag.
I will certainly try the breaker bar-belt-socket method next.
Thanks so much,
Dan

Daniel5691

A quick follow-on.
After a night's sleep and another 24 hr of PB Blaster, I used DrBob's trick with the belt-socket-breaker bar and gently turned the AC crank pulley clockwise. I made sure to keep the breaker bar aligned in the plane of the pulley.
One single slow tug and a tiny "pop" and appreciable movement at the pulley !
The pulley then (finally) began to wobble and within 30 minutes was off.
The harmonic balancer was a simple 60 minutes and off easily, the HB "wobbled" ever-so-slightly with the very first tug.

THANK YOU DR BOB.

Note to future n00bs: just relax and take your time with the AC pulley and balancer. It was all about very VERY VERY small light movements by hand in the end. You cannot force these parts to obey. They have to be coaxed in every sense of the word. It may take you what seems like forever, but don't give up and don't go postal on the parts. Believe me, if mine came off, yours will too. Yes, it took a total of 5 days and about 7 hours of work, 5 1/2 of which seemed totally useless to me. The frustration level was 10/10.
But, nothing was damaged, and I'm ready for the next step.
Dan

Daniel5691

I also now realize that at current hourly rates for mechanic's labor,
I would go broke within about 8.215 minutes if I were doing this for a living.

I don't see how you "real" mechanics do this ! ! ! !