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I was trying to undo my crankshaft pulley bolt, with the engine locked using the locking tool, and the crankshaft now turns without the pulley turning!!!! I believe this means the woodruff key has sheared off my pully. Does anyone know how I can lock the engine to get this bolt out, without damaging the gear box!!!!!!!
I hope there is a solution to this, as I fear this may write my engine off!!
I'm afraid that I could not understand your problem correctly. But as far I understand, you locked the belt pulley, which drives hydraulic pump and stuff. There were some problems, and now you need to get big bolt out to check what happened right ? So there is risky and dirty solution. You buy big cheap and good screwdriver. I don't know is it possible for you, but our local tools shop sels these, made in chinia, but good (sounds impossible). I mean really big, from good steel. You can try to brake end of it if you wil be successfull, then go find another, which is stronger . Take crankshaft reference sensors out WITH the plate of alloy which holds them. You will see flywheel teeth and a place where to hold screwdriver. Now the most important part is to match big screwdriver and these tooths. Some machining may be needed. Using some mind and force (force alone will break tooths or gearbox case 100%), also another pair of hands (a must) you can lock engine. IMPORTANT! THIS IS BAD SOLUTION! It must be used only in case you cannot lock crankshaft otherwise (which I believe is your situation). It is NOT GOOD for bearings, crankshaft, and of course of flywheel teeth. If you will break one, it is not the end of the world, this wil mean, you will need to maintain your starter more offten . If you will brake two, YOU WILL NEED TO CHANGE FLYWHEEL.
If you will brake two, YOU WILL NEED TO CHANGE FLYWHEEL.
Where do you get this info from ? If you dont know what you are talking about then don`t talk please. The teeth are not a part of the flywheel, it`s a loose teethed ring wich is shrinked on to the flywheel.
Try locking the engine by sticking it in gear and applying the brakes. If the bolt was tightend by factory or a professional it was tightened to 350nm with the special VAG tool or 450nm without it. Loosening it requiers considerable force.
Where do you get this info from ? If you dont know what you are talking about then don`t talk please. The teeth are not a part of the flywheel, it`s a loose teethed ring wich is shrinked on to the flywheel.
I have a car with one tooth missing on this flywheel. I know, I'm stupid , also I've seen, that you can buy ring of teeth separately. However I have tried to take this ring off, but unsuccessfully. Maybe special equipment or maybe knowledge of some tricks is needed, but I could not disassemble fllywheel myself. So I've bought new bolts and changed whole flywheel.
Sau
200 20vt 88' 3b, human carrier
CQ typ85 with AAN inside, see project blog at http://kwlw.blogspot.com
I was trying to undo my crankshaft pulley bolt, with the engine locked using the locking tool, and the crankshaft now turns without the pulley turning!!!! I believe this means the woodruff key has sheared off my pully. Does anyone know how I can lock the engine to get this bolt out, without damaging the gear box!!!!!!!
I hope there is a solution to this, as I fear this may write my engine off!!
S2Roo
hi s2roo
have you taken the 4 allen key bolts out of the centre of crank pulley?
put them back in and try again,
i had same problems as you until i seen my mistake
hope its as easy as that
Nice one, if you lock the engine by holding it by the flywheel, you have a fair chance of bending the crankshaft. Believe me, I have already seen this. Breaking 1 or 2 teeth on the starter ring also means flywheel out job. Nice!!!
Mihnea
Originally posted by Gringo
Where do you get this info from ? If you dont know what you are talking about then don`t talk please. The teeth are not a part of the flywheel, it`s a loose teethed ring wich is shrinked on to the flywheel.
Try locking the engine by sticking it in gear and applying the brakes. If the bolt was tightend by factory or a professional it was tightened to 350nm with the special VAG tool or 450nm without it. Loosening it requiers considerable force.
Good luck, you`ll need it ( no pun intended ).
'98 Silver Grey 2.7T S4, dual 2.75" turbo back exhaust with no cats, FMIC, BIG injectors, 10 Bar motorsport fuel pump, modded RS4 turbos, tubular exhaust manifolds, custom intakes, RS4 MAF, Bilstein PSS9, H&R ARBs, 19" BBS CH, custom remap, 511 BHP/505ft-lbs
If I drill the head of the bolt off, how would I get the bolt out? I think it would still be very difficult to get out.
S2roo
OK,
1) After you have drilled or ground off the the head of the bolt, the pulley will come off. You no longer have 350lbs of torque on the bolt.
2) You will have a short stub sticking out of the end of the crank. This should allow you to either drill out the center of the bolt and use an easy out, or use a very large type of vice grips. Without torque on the bolt, it should come out.
Just one possiblity
Greg
They can have my car when they pry my cold dead fingers from the steering wheel.
I dont know how to repair this but i get the screw from the pulley with An air screwdriver thats is for unbolt wheels from Tracktors (farmer cars) a REAL big one! That was done without any locking tool! I could not unscrew it with the locking tool and a normal air pistol from the Garage!
The only correct way to lock the engine is from the front pulley with original tool or self made similar tool. All others may do damage. Believe me.
But the tool is no longer an option ....
I still think locking it in gear and applying the brakes should do the trick. I wouldn`t worry to much about the gearbox as it handles a lot more Nm than 450Nm in a tuned car.
Footnote;
To replace teeth on the flywheel. Undo flywheel. Chisel the broken one of without damaging the actual flywheel. The new one has to be heated quite a bit before installation. Use a propane burner or acetylene torch. Ease the new ring into place with a pair of pliers and let cool. When it cools it shrinks and jams itself in place.
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. Take crankshaft reference sensors out WITH the plate of alloy which holds them. You will see flywheel teeth and a place where to hold screwdriver. Now the most important part is to match big screwdriver and these tooths. Some machining may be needed. Using some mind and force (force alone will break tooths or gearbox case 100%), also another pair of hands (a must) you can lock engine. IMPORTANT! THIS IS BAD SOLUTION! It must be used only in case you cannot lock crankshaft otherwise (which I believe is your situation). It is NOT GOOD for bearings, crankshaft, and of course of flywheel teeth. If you will break one, it is not the end of the world, this wil mean, you will need to maintain your starter more offten 
, also I've seen, that you can buy ring of teeth separately. However I have tried to take this ring off, but unsuccessfully. Maybe special equipment or maybe knowledge of some tricks is needed, but I could not disassemble fllywheel myself. So I've bought new bolts and changed whole flywheel. 
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