Feather Key Removal

[RedMeanzGo]

This thing will not budge... I've tried diagonal cutters, pliers, penetrating oil, and a small pry bar. Obviously damaged it quite a bit. I don't know how many chances I have left... Can I heat this up with a torch to try and remove it, or will that cause damage to the Crankshaft, or possibly some other component ? If so, how long should I heat it for ? My last resort is to try and drive a self tapping screw in there, and yank it out...

[Belgian951]

My technique was as follows:

1) Blast it with a bit of penetrating oil, let it soak
2) Blast it again
3) Take cutting pliers (see https://cvszonwering.be/wp-content/uplo ... Pliers.png) and put them horizontally aligned with the crankshaft. Close the pliers, you'll be able to let the pliers 'bite' with the lowest part of the pliers (hope that makes sense). Then leverage the pliers against the crankshaft to pull the key up.
4) Alternatively, use a pair of tongs (see https://i.etsystatic.com/8852908/r/il/7 ... 3_8st9.jpg) and put them over the key, so that you can grip the most surface area as possible. Clamp down and wiggle a bit until loose.

Hope this helps!

[Tom]

I've had better luck with the second type of pliers (aka end snips or bullnose), but those keys can be a real pain. I'd order a new one now because chances are good yours will be mangled when you finally get it out. My technique of last resort is to use a sharp chisel and a hammer. Put the chisel on the leading end and drive it in the key until you can use the chisel to pry it up.

[RedMeanzGo]

So I lost my nerve and ended up drilling a self tapping screw into it, and yanking it out. It worked, but I may be in a bit of trouble because I ended up actually drilling through the crankshaft.... UGHHHHH ! What do you guys think of this ? After looking at it for about 45 minutes, I thought I'm either going to have to replace the entire crankshaft, or theres a chance it may not be a big deal at all. There will just be a little hole under the new key.

[Tom]

Ok... well, that's a new one. Sorry that happened, but my gut says it's probably ok. I'd try screwing the big front bolt in to make sure it still turns in smoothly and doesn't get snagged where the hole is (if it goes in that deep). You can make a thread chaser by cutting a few slots down the side of a bolt that size. I'm sure you could also order a proper thread chaser in that size too, though probably not cheap. I can't imagine that would weaken the crank or throw off its balance in any meaningful way. But that's nothing more than my intuition, unfettered by any relevant education, training, or experience. I'd be curious what @michaelmount123 thinks?

[cda951]

The go-to for removing woodruff keys (American term) is top-cutting pliers as linked below, grips the key along its entire length and can bear against the crankshaft snout to remove the key.

I don't think the hole in the crankshaft snout is an issue, it's not like the center of the crankshaft is filled with oil!

Heed Tom's advice about threading in the crankshaft pulley bolt by hand, fill the hole with epoxy or sealant, carefully file the OD of the keyway and install a new woodruff key and move on.

https://www.fcpeuro.com/products/7-1-4- ... IbEALw_wcB

[Tom]

The go-to for removing woodruff keys (American term) is top-cutting pliers as linked below, grips the key along its entire length and can bear against the crankshaft snout to remove the key.

I don't think the hole in the crankshaft snout is an issue, it's not like the center of the crankshaft is filled with oil!

Heed Tom's advice about threading in the crankshaft pulley bolt by hand, fill the hole with epoxy or sealant, carefully file the OD of the keyway and install a new woodruff key and move on.

https://www.fcpeuro.com/products/7-1-4- ... IbEALw_wcB

If Chris thinks it's ok, it's ok

Glad you mentioned the feather key thing. I've always called them woodruff keys too, and have never heard anyone call them anything else, so I googled it. I guess in some technical circles a woodruff key has a rounded bottom side and a feather key has a flat bottom. Certainly news to me.

https://engineeringproductdesign.com/kn ... s-keyways/

[michaelmount123]

Now that the area around the key slot is somewhat boogered (we've all done it), take a strip of emory paper and "shoe shine" it over the nicked up area. This will allow you or the next guy to slide the washer and oil pump drive off the snout, not to mention allow the cam drive gear to go back on easily. You're going to replace your key, right?

You can often remove the key easily by tapping one end straight down with a soft brass punch. It usually causes the other end to pop up. Magic, I think.

Ignore the hole you've made. It won't hurt anything as long as the new key can sit flat and the crank bolt goes in/out easily.
MM

[RedMeanzGo]

Thank you for all the replies ! I am going to replace the key, and I just picked up some emory cloth to attack those nicks on the shaft. I really want to thank you guys for not making feel worse than I already feel about this. I'll be the first to admit I'm certainly not the smartest guy around, but I appreciate having a place to share my mistakes without getting beat up for making them. Hopefully someone else will read this and not repeat what I did !

[Tom]

Thank you for all the replies ! I am going to replace the key, and I just picked up some emory cloth to attack those nicks on the shaft. I really want to thank you guys for not making feel worse than I already feel about this. I'll be the first to admit I'm certainly not the smartest guy around, but I appreciate having a place to share my mistakes without getting beat up for making them. Hopefully someone else will read this and not repeat what I did !

Many years ago, my brother had an early Toyota HiLux truck -- a '70 if memory serves, with the fog lights up on the fenders. We'd drive all over in that thing back in high school. One day, the exhaust hangers completely rusted through, and the exhaust started scraping on the ground. With no money or welding skills, we hatched a plan to make our own exhaust supports out of old fence boards that were just rotting away in the yard. After a few hours, the exhaust was good as new, and did just fine on our celebratory test ride to McDonalds. The next day, we drove maybe 20-30 miles to our grandparents' house for a family event. About half way there, we started smelling a fire in the area. It kept smelling stronger and stronger. Once we got there, we realized the fire was actually our wood exhaust hangers smoldering away like yule logs -- which of course started flaming up as soon as the truck stopped. We were super lucky to be in the driveway right next to a garden hose -- otherwise it could have been a real disaster.

Drilling a little hole is nothing. You're among friends here.