Crankshaft damper pulley came loose!

It is a 89 Volvo 240 GL. Car overheated, had electrical problem, and the
power steering quit all at once. Found that the triple-crankshaft pulley (It
is called a damper pulley, I think?) that drives all the accessories had
come loose from the crankshaft! The engine still runs, but is not turning
the crankshaft pully. When it came loose, one of the belts was putting a
sideways force on it, so the crankshaft (continuing to turn) wallered out a
section of the pulley inner surface (only on one side of its circumference),
resulting in the pulley being found sitting on the crankshaft at an angle of
about 20 deg. off the straight axis. But suprisingly ( I guess the
crankshaft is a harder material?), the crankshaft itself *appears*
undamaged. When I removed the loose pulley, it was obvious how this could
happen....there is no key or set screw, it was apparently just press-fitted
on!
Now I am really screwed, as I can't see how I could ever get a new
pulley securely press-fitted on when it is right up next to the fan and
radiator. And even if I lifted the engine out of the car so that I could
really wack it on hard with a mallet, it would still be likely to come loose
again. Why is there no square key on the shaft to positively lock it on?
Also, there is nothing to set the timing mark at the proper place when the
new pulley is installed.
Can I maybe buy a pulley for this car that has a set-screw, that
secures to a threaded hole drilled into the crankshaft? But then I would
have to have the car towed to a garage to have this done, as drilling and
tapping a hole in the crankshaft end is probably more than I should try to
do myself. Advice? I need to get it fixed very soon. Thanks, Jim

 

The crankshaft pulley does have a notch cut out so it lines up with the
crankshaft
You have to remove the cooling fan to gain access to perform this repair
Yes there is a bolt that holds the pulley in to the crankshaft & if it is
not tightened to the correct torque setting it will become loose make sure
that the bolt did not Break Off in the crankshaft. If you are unable to find
a notch on the crankshaft pulley that is on the car you will have to replace
the crankshaft Gear
Post back & will Try to help further
Glenn

--
"*-344-*Never Forgotten"
Is for the New York City Firemen who lost their lives on September 11,2001.
The official count is 343, but there was also a volunteer who lost his life
aiding in the initial rescue efforts. And I will never forget them as long
as I live,
nor should any American.
"Mow Green"

 

Hi GLenn! I looked at the damper pulley again. As I said there is NO bolt,
or even any bolt-hole on it. It would have to be at the bottom of one of the
three belt grooves, wouldn't it? (well, that would be for something like a
set-screw) There is no way it was ever locked on. The day before this
happened, I had replaced the alternator, and I could have gotten the belt
more tight than it really should be. I have felt all around the
circumference of the front of the crankshaft that the pully was mounted on,
and it is smooth like a hardened crankshaft should be, and there is no bolt
hole. There is a V-groove in the middle going around its
circumference....but not any axial groove such as you would have for a
square key. So there is NOTHING to positively secure the new pulley to the
shaft. I guess I will go ahead and order a new pulley and go from there.
Then I will see what sort of bolt securing device it has. Glenn, this is
probably something that is special order from Autozone. Is there some
internet co. that can supply one quickly?

 

I think that your pulley is broken. There is an inner part held to the
end of the crank with that big bolt in the center. There is a layer of
rubber, then the outer part where the belts ride. I think you have the
outer half in your hand, the inner half is still on the crankshaft. Go
to http://www.thepartsbin.com (or your favourite online supplier) and
look up the crankshaft pulley for your car and you can see a picture of
what you get.

--
Mike F.
Thornhill (near Toronto), Ont.

NOTE: new address!!
Replace tt with t (twice!) and remove parentheses to email me directly.
(But I check the newsgroup more often than this email address.)

 

The pully should be bolted on.

 

Yea, there is an outer part of the pulley bonded to an inner part by rubber.
Not a trace of the rubber was left on either part! Once I jacked the car and
looked at the crankshaft end from underneath, I could then see that big bolt
holding on the inner part. Thanks all. Jim

 

This recently happened to my brother in law in his Astron II Mitsubishi.
New part was near 400 dollars, wreckers had one for 33. Easy enough job on
that though we had to unbolt and lower the motor to get the new pulley on.
Next time it happens, could easily be knocked over in 30 minutes, though
took us a while longer and we dropped the motor slowly down as we no where
near a workshop and had to work on it on uneven ground.

Hammo

 

BTW, with a 3/8 ratchet and 15/16 deep socket, I was able to get the bolt
out and the inner part of the damper pulley off, easily without removing
either the fan or radiator. The ratchet was scraping against the fan shroud
a little, but it worked.