Crankshaft pulley/crankshaft/key MAJOR PROBLEM

[brian.evans]

The car is a 93 LX D15B7 with 131,000 miles. It runs like a top, recently getting 33.5 mpg running mostly 80 mph interstate. I say that to say this; I'd like to save this car if at all possible.

Yesterday my power steering belt randomly slipped of the pulley. I put it back on and retensioned the belt, thinking maybe it was just a random thing. Today when I pulled out of work it slipped the belt again. I said screw it and started driving home. About ten miles later my battery light came on. Great! Now my alternator quit! I limped it home and pulled the alternator. It tested fine, so I got to thinking and looking deeper. It was so obvious, but I never even thought about it. My crankshaft pulley was wobbling like crazy.

I used the impact and pulled it. What I found has made me sick. It looks like the bolt backed off, the key sheared, and the key ways are screwed.

Am I looking at a crankshaft replacement as the only fix? I really love this car, but a crank replacement is a bit too much work. It has a fresh head job and all the routine maintenance at 100k. It could go for 200,000 more miles.

What are my options?

 

[jameswanser]

Sorry to hear. I'm still trying to figure out how the keyway got jacked up, since the crank and pulley are a HELL of a lot harder than that key. If the keyway on the crank is that bad, I can't think of any way to repair without removing the crank (and by that point, likely better to just replace crank rather than try to fix the old one)

 

[jameswanser]

with some pics, perhaps someone can give a better suggestion

 

[brian.evans]

Ahhh....apparently the pictures didn't post in the original post. Let's try this again.

 

[lethal6]

Ouch. That crankshaft definitely looks fubar. Unfortunately, from what I have seen, you are going to have to pull it and replace it. At the least, there is no fixing that crankshaft in the car.

 

[brian.evans]

Yeah.....That's kinda what I thought. So, today I bought a Volvo S40 1.9 I Turbo. it's a fun car.

 

[jameswanser]

wow. I wouldn't have thought that even possible, but clearly it is. Almost like the crank pulley was held stationary and the someone tried to turn over the engine.