I haven't posted on the forum since I'm not very experienced and don't feel I really have much to contribute to this forum, but I may have something after changing the timing belt in my '96 Legacy L wagon.

 

The crank pulley was severely overtorqued (didn't come loose with either my dad or I on a breaker bar in 5th gear, e brake on, braced against the passenger's fender with ~1/2 revolution) and as it turned out had RTV as a Loctite substitute.

 

My dad has a Bridgeport mill, so that's how I made the tool, but it could be done with a drill press and band saw in a pinch. Dimensions are the following:

5/16" Gr 8 bolts on 3.15" centers

1.25" center hole

1" flats for holding with a wrench

 

It took me about 2 hours, but would take less time if fly cutting, digging tools out of the mess of a shop, precision machining, etc. aren't an issue.

Breaker bar against the frame or against the ground  and blip of the starter has never failed for me.

 

O.

I made one for my '03 H6, 3 pieces of 16ga sheet brazed together, 4 Grade 8 bolts.

 

 

Edited February 18, 201313 yr by CNY_Dave

Crank pulley bolt removal is super easy. You use a deep socket, old 1/2" ratchet, and a 4 lb hammer. Inertia does the work. Hysteresis is your friend. I've probably removed 1000 pulley bolts with no fuss. Loctite or not - doesn't matter. 

 

GD

But that method won't work with a torque wrench...

But that method won't work with a torque wrench...

Why would you be using a torque wrench to remove a large bolt though?

I assume at some point someone puts the bolt back in...

I assume at some point someone puts the bolt back in...

And hopefully to the right torque