February 22, 20179 yr I had just replaced timing belt on 09 Forester, and somehow managed to destroy the key when tightening the crank pulley / balancer. Part of the key is embedded in the backside of the balancer partially in the keyway, and the remains is smashed up against the crankshaft sprocket that drives the timing belt, and at the top is spread out to about 6.5 mm in width vs, the approx 5 mm width of the keyway. Not much to try and grip onto, and I wanted to get an idea of the options open to me to get the remains of the key out so I can install a new balancer, Has any one run into this situation before ? Thanks for any help you can provide ! Doug If needed, I will try to post a couple of photos tomorrow - right now it's dark and snowing..
February 22, 20179 yr Die grinder with a cut off wheel. You'll have to grind it down till you can get the sprocket off the crank. Destroy the sprocket if you have to. They are only about $35 from the dealer. Key is cheap too. GD Edited February 22, 20179 yr by GeneralDisorder
February 22, 20179 yr Author After grinding down key, what is best way to remove sprocket and the part of the key still embedded in the crank? Thanks, Doug
February 22, 20179 yr There are holes in the sprocket that are exactly the correct size for tapping to 8x1.25mm thread. Use a steering wheel puller to remove the sprocket. The key will come right out once the sprocket is removed. GD
February 22, 20179 yr Don't forget to use a cutting fluid when tapping those holes. If you have a good hardware nearby, they'll have something. If not, just search online for "tapping fluid" just about anything that comes up will work fine. Once you have the pieces apart, if you can see the broken pieces of the woodruff key, try knocking them out with a flathead screwdriver you don't care about. If you're feeling brave, WD40 will do in a pinch, just make sure you're using a new tap
February 22, 20179 yr Tap into the key with a small chisel and use that to pry the key out. New key should slip right in.
February 22, 20179 yr pics at bottom of page 2 http://www.ultimatesubaru.org/forum/topic/149417-harmonic-balancer-quit-spinning/page-2 i think i used a 7mm tap. Bolts that work are hard to find at 7mm though. seriously this was on 96 legacy 2.2
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