Triple groove crank pulley

1
Hi all,

I am trying to transplant my power steering from my invalid Syncro into my "New Syncro".
One problem is that the new one has only a 1 grove pulley.
For the power steering pump I need another groove. 
I have to take the triple groove off and move it into the new van.
Problem: 350 Nm  (258 ft lb) of torque needed to undo the nut.
VW has a special tool. Anyone with an idea how to do this. 
Home made tools?
 
Tom
2
My bush mechanics method is to stop the flywheel by inserting a good screwdriver into one of the holes in it from the top left hand side of engine then undo the nut with a breaker bar. Worked many times for me.Eddie.
3
Eddy, possibly the only way to get it off if no VW gadget on hand. 
If you allow me to add a few points to make it easier to understand for someone who hasn't done it yet.
The hole you are talking about on the left is about 40 mm in dia and is the entry for the clutch housing vent line.
Pull that plug out and insert a screwdriver or round bar , trying to get the tool into one of the holes which carry the bolts (6) to hold the clutch plate . Those holes are just over 10mm in dia so obviously your screwdriver should be about 10mm wide.
Hart

Sent from my iPad

On 7 Jan 2015, at 7:34 pm, "bergodaz@ozemail.com.au [Syncro_T3_Australia]" <Syncro_T3_Australia@yahoogroups.com> wrote:

 

My bush mechanics method is to stop the flywheel by inserting a good screwdriver into one of the holes in it from the top left hand side of engine then undo the nut with a breaker bar. Worked many times for me.Eddie.

4
Spot on Hart!
5
Hi Hartmut and all,
From memory, years back when I experimented with this trick to lock the pulley into place prior to attempting to remove the pulley nut, an even finer tolerance fit tool (to stop any slop in the fit) was to use a 3/8th inch allen key (if you have one!) rather than a 10mm. Using the allen key, no chance then you are going to shear off the part that's poked in through the hole.
Cheers.
Ken


To: Syncro_T3_Australia@yahoogroups.com
From: Syncro_T3_Australia@yahoogroups.com
Date: Wed, 7 Jan 2015 20:55:57 +1100
Subject: Re: [Syncro_T3_Australia] Re: Triple groove crank pulley

 

Eddy, possibly the only way to get it off if no VW gadget on hand. 
If you allow me to add a few points to make it easier to understand for someone who hasn't done it yet.
The hole you are talking about on the left is about 40 mm in dia and is the entry for the clutch housing vent line.
Pull that plug out and insert a screwdriver or round bar , trying to get the tool into one of the holes which carry the bolts (6) to hold the clutch plate . Those holes are just over 10mm in dia so obviously your screwdriver should be about 10mm wide.
Hart

Sent from my iPad

On 7 Jan 2015, at 7:34 pm, "bergodaz@ozemail.com.au [Syncro_T3_Australia]" <Syncro_T3_Australia@yahoogroups.com> wrote:

 
My bush mechanics method is to stop the flywheel by inserting a good screwdriver into one of the holes in it from the top left hand side of engine then undo the nut with a breaker bar. Worked many times for me.Eddie.

6
Ken, you are right, if one uses an Allen key you have to use a 3/8" as it measures 10.8 mm over the it's outer circumference and the holes in the flywheel are  11 mm, perfect fit.  
What about the socket to get the 32 mm bolt undone ? Have you got a shortened one ? 
There is hardly enough room to get a standard one in.
Hartmut

Sent from my iPad

On 7 Jan 2015, at 10:30 pm, "Ken Garratt unclekenz@hotmail.com [Syncro_T3_Australia]" <Syncro_T3_Australia@yahoogroups.com> wrote:

 

Hi Hartmut and all,
From memory, years back when I experimented with this trick to lock the pulley into place prior to attempting to remove the pulley nut, an even finer tolerance fit tool (to stop any slop in the fit) was to use a 3/8th inch allen key (if you have one!) rather than a 10mm. Using the allen key, no chance then you are going to shear off the part that's poked in through the hole.
Cheers.
Ken


To: Syncro_T3_Australia@yahoogroups.com
From: Syncro_T3_Australia@yahoogroups.com
Date: Wed, 7 Jan 2015 20:55:57 +1100
Subject: Re: [Syncro_T3_Australia] Re: Triple groove crank pulley

 

Eddy, possibly the only way to get it off if no VW gadget on hand. 
If you allow me to add a few points to make it easier to understand for someone who hasn't done it yet.
The hole you are talking about on the left is about 40 mm in dia and is the entry for the clutch housing vent line.
Pull that plug out and insert a screwdriver or round bar , trying to get the tool into one of the holes which carry the bolts (6) to hold the clutch plate . Those holes are just over 10mm in dia so obviously your screwdriver should be about 10mm wide.
Hart

Sent from my iPad

On 7 Jan 2015, at 7:34 pm, "bergodaz@ozemail.com.au [Syncro_T3_Australia]" <Syncro_T3_Australia@yahoogroups.com> wrote:

 
My bush mechanics method is to stop the flywheel by inserting a good screwdriver into one of the holes in it from the top left hand side of engine then undo the nut with a breaker bar. Worked many times for me.Eddie.

7
Thanks for the hints.
I have dropped the exhaust heat shield. A normal socket will then fit onto the bolt. I have not attempted to undo it yet.
 
Tom

From: "Hartmut Kiehn hartis@live.com.au [Syncro_T3_Australia]" <Syncro_T3_Australia@yahoogroups.com>
To: "Syncro_T3_Australia@yahoogroups.com" <Syncro_T3_Australia@yahoogroups.com>
Sent: Thursday, 8 January 2015, 9:04
Subject: Re: [Syncro_T3_Australia] Re: Triple groove crank pulley

 
Ken, you are right, if one uses an Allen key you have to use a 3/8" as it measures 10.8 mm over the it's outer circumference and the holes in the flywheel are  11 mm, perfect fit.  
What about the socket to get the 32 mm bolt undone ? Have you got a shortened one ? 
There is hardly enough room to get a standard one in.
Hartmut

Sent from my iPad



On 7 Jan 2015, at 10:30 pm, "Ken Garratt unclekenz@hotmail.com [Syncro_T3_Australia]" <Syncro_T3_Australia@yahoogroups.com> wrote:

 
Hi Hartmut and all,
From memory, years back when I experimented with this trick to lock the pulley into place prior to attempting to remove the pulley nut, an even finer tolerance fit tool (to stop any slop in the fit) was to use a 3/8th inch allen key (if you have one!) rather than a 10mm. Using the allen key, no chance then you are going to shear off the part that's poked in through the hole.
Cheers.
Ken


To: Syncro_T3_Australia@yahoogroups.com
From: Syncro_T3_Australia@yahoogroups.com
Date: Wed, 7 Jan 2015 20:55:57 +1100
Subject: Re: [Syncro_T3_Australia] Re: Triple groove crank pulley

 

Eddy, possibly the only way to get it off if no VW gadget on hand. 
If you allow me to add a few points to make it easier to understand for someone who hasn't done it yet.
The hole you are talking about on the left is about 40 mm in dia and is the entry for the clutch housing vent line.
Pull that plug out and insert a screwdriver or round bar , trying to get the tool into one of the holes which carry the bolts (6) to hold the clutch plate . Those holes are just over 10mm in dia so obviously your screwdriver should be about 10mm wide.
Hart

Sent from my iPad

On 7 Jan 2015, at 7:34 pm, "bergodaz@ozemail.com.au [Syncro_T3_Australia]" <Syncro_T3_Australia@yahoogroups.com> wrote:

 
My bush mechanics method is to stop the flywheel by inserting a good screwdriver into one of the holes in it from the top left hand side of engine then undo the nut with a breaker bar. Worked many times for me.Eddie.



8
Hi Hartmut,
My pulley nut suits a 30mm socket and yes, I reduced its length to suit the nut depth. I gained additional access  space by also forcing the rear tinware back using a homemade spreader made of threaded rod, nuts and washers. To stop the socket slipping off the nut, I filled the space left between the top of the wrench and the tinware using a timber packer (wedge) piece.
In this case, the purpose of the exercise was to figure out this bushmans way of nut removal for future use, not then and there at the time.
Cheers.
Ken


Sent from my Samsung GALAXY S4


-------- Original message --------
From: "Hartmut Kiehn hartis@live.com.au [Syncro_T3_Australia]"
Date:08/01/2015 9:04 AM (GMT+10:00)
To: Syncro_T3_Australia@yahoogroups.com
Subject: Re: [Syncro_T3_Australia] Re: Triple groove crank pulley

 

Ken, you are right, if one uses an Allen key you have to use a 3/8" as it measures 10.8 mm over the it's outer circumference and the holes in the flywheel are  11 mm, perfect fit.  
What about the socket to get the 32 mm bolt undone ? Have you got a shortened one ? 
There is hardly enough room to get a standard one in.
Hartmut

Sent from my iPad

On 7 Jan 2015, at 10:30 pm, "Ken Garratt unclekenz@hotmail.com [Syncro_T3_Australia]" <Syncro_T3_Australia@yahoogroups.com> wrote:

 

Hi Hartmut and all,
From memory, years back when I experimented with this trick to lock the pulley into place prior to attempting to remove the pulley nut, an even finer tolerance fit tool (to stop any slop in the fit) was to use a 3/8th inch allen key (if you have one!) rather than a 10mm. Using the allen key, no chance then you are going to shear off the part that's poked in through the hole.
Cheers.
Ken


To: Syncro_T3_Australia@yahoogroups.com
From: Syncro_T3_Australia@yahoogroups.com
Date: Wed, 7 Jan 2015 20:55:57 +1100
Subject: Re: [Syncro_T3_Australia] Re: Triple groove crank pulley

 

Eddy, possibly the only way to get it off if no VW gadget on hand. 
If you allow me to add a few points to make it easier to understand for someone who hasn't done it yet.
The hole you are talking about on the left is about 40 mm in dia and is the entry for the clutch housing vent line.
Pull that plug out and insert a screwdriver or round bar , trying to get the tool into one of the holes which carry the bolts (6) to hold the clutch plate . Those holes are just over 10mm in dia so obviously your screwdriver should be about 10mm wide.
Hart

Sent from my iPad

On 7 Jan 2015, at 7:34 pm, "bergodaz@ozemail.com.au [Syncro_T3_Australia]" <Syncro_T3_Australia@yahoogroups.com> wrote:

 
My bush mechanics method is to stop the flywheel by inserting a good screwdriver into one of the holes in it from the top left hand side of engine then undo the nut with a breaker bar. Worked many times for me.Eddie.

9
Hi all. I made a spanner for the pulley bolt by cutting down an old 30mm socket and welding a flat bar handle on it. It can be slipped between the pulley and the tin. Handy for turning over the engine to find TDC. Small enough to fit in the toolbox. Slip a pipe over the handle if you need more leverage.

Roger Beetle Bayley
10
Hi all,

Power steering is in and working. 
Now I have to go to the Gym to get my exercise instead of turning the steering wheel.
Thanks to good advice the crank nut was done easy. 
Standard 30mm nut and breaker bar with extension did it.
The power steering pump and rack transferred well.
The hydraulic lines had some rub marks from where they touched the body. 
Nothing too serious.
Time intensive but worth it.
*:P tongue
 Tom

From: "unclekenz unclekenz@hotmail.com [Syncro_T3_Australia]" <Syncro_T3_Australia@yahoogroups.com>
To: Syncro _T3_Australia forum <Syncro_T3_Australia@yahoogroups.com>
Sent: Thursday, 8 January 2015, 23:19
Subject: Re: [Syncro_T3_Australia] Re: Triple groove crank pulley

 
Hi Hartmut,
My pulley nut suits a 30mm socket and yes, I reduced its length to suit the nut depth. I gained additional access  space by also forcing the rear tinware back using a homemade spreader made of threaded rod, nuts and washers. To stop the socket slipping off the nut, I filled the space left between the top of the wrench and the tinware using a timber packer (wedge) piece.
In this case, the purpose of the exercise was to figure out this bushmans way of nut removal for future use, not then and there at the time.
Cheers.
Ken


Sent from my Samsung GALAXY S4


-------- Original message --------
From: "Hartmut Kiehn hartis@live.com.au [Syncro_T3_Australia]"
Date:08/01/2015 9:04 AM (GMT+10:00)


To: Syncro_T3_Australia@yahoogroups.com
Subject: Re: [Syncro_T3_Australia] Re: Triple groove crank pulley

 
Ken, you are right, if one uses an Allen key you have to use a 3/8" as it measures 10.8 mm over the it's outer circumference and the holes in the flywheel are  11 mm, perfect fit.  
What about the socket to get the 32 mm bolt undone ? Have you got a shortened one ? 
There is hardly enough room to get a standard one in.
Hartmut

Sent from my iPad

On 7 Jan 2015, at 10:30 pm, "Ken Garratt unclekenz@hotmail.com [Syncro_T3_Australia]" <Syncro_T3_Australia@yahoogroups.com> wrote:

 
Hi Hartmut and all,
From memory, years back when I experimented with this trick to lock the pulley into place prior to attempting to remove the pulley nut, an even finer tolerance fit tool (to stop any slop in the fit) was to use a 3/8th inch allen key (if you have one!) rather than a 10mm. Using the allen key, no chance then you are going to shear off the part that's poked in through the hole.
Cheers.
Ken


To: Syncro_T3_Australia@yahoogroups.com
From: Syncro_T3_Australia@yahoogroups.com
Date: Wed, 7 Jan 2015 20:55:57 +1100
Subject: Re: [Syncro_T3_Australia] Re: Triple groove crank pulley

 

Eddy, possibly the only way to get it off if no VW gadget on hand. 
If you allow me to add a few points to make it easier to understand for someone who hasn't done it yet.
The hole you are talking about on the left is about 40 mm in dia and is the entry for the clutch housing vent line.
Pull that plug out and insert a screwdriver or round bar , trying to get the tool into one of the holes which carry the bolts (6) to hold the clutch plate . Those holes are just over 10mm in dia so obviously your screwdriver should be about 10mm wide.
Hart

Sent from my iPad

On 7 Jan 2015, at 7:34 pm, "bergodaz@ozemail.com.au [Syncro_T3_Australia]" <Syncro_T3_Australia@yahoogroups.com> wrote:

 
My bush mechanics method is to stop the flywheel by inserting a good screwdriver into one of the holes in it from the top left hand side of engine then undo the nut with a breaker bar. Worked many times for me.Eddie.



11
Great work Tom,

I need to do this to a spares motor of mine as I owe it to the bloke I bought the new 2wd engine from for my white 2wd caravelle.

I was hoping you would work it all out.

I only have a flex plate to install on it as I transferred my flywheel to the new motor - it has 3 holes which line up with the inspection hole so I should be able to lock that and break out the bastard bar to get the nut off. There is a woodruff key there too I believe....

Cheers,

Skot


On 13/01/2015 7:42 AM, Tom Mischler energysustained@ymail.com [Syncro_T3_Australia] wrote:
Hi all,

Power steering is in and working.
Now I have to go to the Gym to get my exercise instead of turning the steering wheel.
Thanks to good advice the crank nut was done easy.
Standard 30mm nut and breaker bar with extension did it.
The power steering pump and rack transferred well.
The hydraulic lines had some rub marks from where they touched the body.
Nothing too serious.
Time intensive but worth it.
*:P tongue
Tom

From: "unclekenz unclekenz@hotmail.com [Syncro_T3_Australia]" <Syncro_T3_Australia@yahoogroups.com>
To: Syncro _T3_Australia forum <Syncro_T3_Australia@yahoogroups.com>
Sent: Thursday, 8 January 2015, 23:19
Subject: Re: [Syncro_T3_Australia] Re: Triple groove crank pulley

Hi Hartmut,
My pulley nut suits a 30mm socket and yes, I reduced its length to suit the nut depth. I gained additional access space by also forcing the rear tinware back using a homemade spreader made of threaded rod, nuts and washers. To stop the socket slipping off the nut, I filled the space left between the top of the wrench and the tinware using a timber packer (wedge) piece.
In this case, the purpose of the exercise was to figure out this bushmans way of nut removal for future use, not then and there at the time.
Cheers.
Ken


Sent from my Samsung GALAXY S4


-------- Original message --------
From: "Hartmut Kiehn hartis@live.com.au [Syncro_T3_Australia]"
Date:08/01/2015 9:04 AM (GMT+10:00)


Subject: Re: [Syncro_T3_Australia] Re: Triple groove crank pulley

Ken, you are right, if one uses an Allen key you have to use a 3/8" as it measures 10.8 mm over the it's outer circumference and the holes in the flywheel are 11 mm, perfect fit.
What about the socket to get the 32 mm bolt undone ? Have you got a shortened one ?
There is hardly enough room to get a standard one in.
Hartmut

Sent from my iPad

On 7 Jan 2015, at 10:30 pm, "Ken Garratt unclekenz@hotmail.com [Syncro_T3_Australia]" <Syncro_T3_Australia@yahoogroups.com> wrote:

Hi Hartmut and all,
From memory, years back when I experimented with this trick to lock the pulley into place prior to attempting to remove the pulley nut, an even finer tolerance fit tool (to stop any slop in the fit) was to use a 3/8th inch allen key (if you have one!) rather than a 10mm. Using the allen key, no chance then you are going to shear off the part that's poked in through the hole.
Cheers.
Ken


To: Syncro_T3_Australia@yahoogroups.com
From: Syncro_T3_Australia@yahoogroups.com
Date: Wed, 7 Jan 2015 20:55:57 +1100
Subject: Re: [Syncro_T3_Australia] Re: Triple groove crank pulley


Eddy, possibly the only way to get it off if no VW gadget on hand.
If you allow me to add a few points to make it easier to understand for someone who hasn't done it yet.
The hole you are talking about on the left is about 40 mm in dia and is the entry for the clutch housing vent line.
Pull that plug out and insert a screwdriver or round bar , trying to get the tool into one of the holes which carry the bolts (6) to hold the clutch plate . Those holes are just over 10mm in dia so obviously your screwdriver should be about 10mm wide.
Hart

Sent from my iPad

On 7 Jan 2015, at 7:34 pm, "bergodaz@ozemail.com.au [Syncro_T3_Australia]" <Syncro_T3_Australia@yahoogroups.com> wrote:

My bush mechanics method is to stop the flywheel by inserting a good screwdriver into one of the holes in it from the top left hand side of engine then undo the nut with a breaker bar. Worked many times for me.Eddie.