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Re: Crankshaft pulley removal - '88 9000T automatic [saabnet.com]
Posted by The Saab Network (more from The Saab Network) on Wed, 1 Jun 2005 11:36:19
In Reply to: Crankshaft pulley removal - '88 9000T automatic [saabnet.com], The Saab Network, Thu, 12 May 2005 11:53:03 
Many thanks to those who responded to my questions on removing the
crankshaft pulley nut.

After originally planning on using the 'bump engine with wrench
perched on crank nut' method, and then considering Syd's 'rope
trick', I ultimately took Herb's advice and purchased an impact
wrench (DeWalt DW059K-2, $255 at Amazon), along with a 30mm impact
socket ($10 at RS Strauss), and a 130 ft-lb torque stick ($25
shipped from torquestick.com).

Removing the crank nut was so easy I thought at first that the
impact wrench wasn't doing anything useful, but the nut came off
in 2 to 3 seconds!

The original crank pulley had completely separated, so after removing
the nut, I removed the inner half of the pulley that remained on
the crankshaft.  It came off easily, along with the oil seal, which
simply slid out.  I also removed the oil pump cover to replace the
O-ring seal, which was brittle enough to break into 3 pieces during
removal.

I then fit a new oil seal into the pump cover, using the inner half
of the old crank pulley as a drift, tapping the seal in with a
rubber mallet against a board laid across the top of the old pulley.
Since the old seal just slid out, I didn't know how deep it had
been installed originally, so I just tapped the new seal in about
1mm below the rim of the oil pump cover, and replaced the cover
onto the oil pump housing.

After installing the new pulley onto the crankshaft, I tightened
the nut using the impact wrench and torque stick.

I goofed though while reinstalling the oil pump cover:  I found
the torque spec for the two large bolts and stupidly assumed that
it was the same for the eight small bolts also.  So I overtightened
the small bolts, and I think I damaged the threads (I didn't torque
them until the wrench clicked at 20 ft-lb, instead of the correct
8 ft-lb, but came very close to that).  I'm hesitant to remove the
bolts and retorque because they are holding now, but I think that
the proper thing to do now would be to repair the threads in the
pump housing.  Has anyone here done this successfully?  If so, did
you use 'helicoils' to do the repair?

Thanks again for taking the time to offer your very kind assistance.

                                                  Ken
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