Well after a week of autoparts stores getting wrong parts, I finally got the right balancer. I had my dad pick it up because I have been working late. The idiot at the Bumper to Bumper store wouldn't let him have the box and only gave him the big key. (I needed the small one)


I went to a different parts store that was open later to get the correct key and they only had a listing for a 6.2L. I bought it hoping it would be the same. It is very close but looks like it might be a little small.


Now the big problem. I stuck it into the crankshaft and the slot is stretched real wide at the top. It is almost enough for the key to tip over when pushed sideway.http://www.dieselplace.com/forum/smileys/Cry.gif


Is there anyway to fix it won't just shear off again?

Maybe; can you send us a photo of it, is the crank slot wide or the pulley slot the one that is wide now.


Key stock is not that difficult to work with, maybe you can custom make one from larger stock "fitted" to your new dimensions, make 2 so you will have spare one handy

This is the best I could get.


http://www.dieselplace.com/forum/uploads/7A6_keyway.jpg

Maybe get in there with a dremel to square up the slot, go with a wider key and also widen the slot in the pulley.


Before that try some JB weld, clean the key and slot so no oil residue remains rough up the slot & key sides so the JB has something to grab, insert the key and fill rounded out side of slot with JB then file down excess until pulley fits.


That may not work a lot of pounding on that crank/pulley it may vibe itself loose, you really need a good metal to metal fit. Print the photo and take to local machine shop & see what they recommend, this could be a tough one to fix as you don't have a lot of room to work it.


If you have to pull the crank to fix it (which may be a possibility) might be a good time to invest in 18:1 pistons.


I taked to another here on the forum, another thought is to press it and then dowel pin it , drill a hole at the crank end & pulley joint use the dowel to lock the pulley to the crank, still a difficult job in ant right, then look for a new crank or take to machine shop have it weld filled and cut new keyway. I have no idea how long it would hold up unless permanent weld repaired or replaced.Edited by: Turbine Doc

The key slot sides need to be parallel to each other and perpendicular to the centerline of the shaft and within close tolerance on width to properly transfer torque. As I posted on the other forum, you will need a new crankshaft.

I just put it back together and will see what happens. I think the picture looks worse than it really is. The gap next to the key was only about 1/16"


It was definately causing the rough idle.