Date:         Tue, 31 Jan 2006 21:54:44 -0600
Reply-To:     Larry Alofs <lalofs@RCN.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Larry Alofs <lalofs@RCN.COM>
Subject:      Re: cracked right side case...i'm in TROUBLE! (was crank pulley
              bolt...argh!)
Content-Type: text/plain; charset=us-ascii; format=flowed

About 6 months ago I needed to replace the harmonic balancer on our Saab
900.  Since the engine on that car is oriented backwards, the bolt on
the end of the crankshaft is toward the firewall and an impact wrench is
not possible.  In fact the clearance is so small that you can only get a
breaker bar on it if you shorten a socket.  I used a Dremel to cut about
3/8 of an inch off a Craftsman socket (hard stuff).  I then found it
nearly impossible to get the bolt loose.  After trying a number of
things, I found a website by a professional Saab mechanic named
Townsend.  Following his advice, I positioned the breaker bar about a
foot from the frame, and hit the starter (ignition disabled).  On the
third try it worked.  Starting with the bar against the frame did not
work; the engine and starter had to build up some angular momentum
before the breaker bar suddenly came to a stop.  Effective, but a little
too exciting.
  A few days ago I discovered that the Hall sensor on that car is now
defective.  Guess where it is...yep, behind the harmonic balancer.
It's always somethin'

Larry A.


rpc wrote:

>Mike,
>  I know this wont help you now, but if anyone else is following your saga, maybe this would help someone, someday:  Not sure if your wedge on the pulley caused the broken piece, but to stop an engine from turning over remove a spark plug. While the piston is down insert a length of rope. Rotate the pulley until piston pushes the rope up to the head. If there is enough rope it will stop the piston and the crankshaft will stop rotating. I used this trick to change the pulley on my 63-1/2 Falcon years ago.
>  Good Luck,
>  Chris C 90MV
>
>  -----Original Message-----
>From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of
>Mike Williams
>Sent: Tuesday, January 31, 2006 2:37 PM
>To: vanagon@GERRY.VANAGON.COM
>Subject: cracked right side case...i'm in TROUBLE! (was crank pulley
>bolt...argh!)
>
>
>and such is life...my luck with vanagons hasn't yet
>changed. i was working on trying to get the crank
>pulley bolt off last night...using my gentle
>persuasion methods (a breaker bar with a pipe over the
>end of it to give more leverage)...i still couldn't
>seem to get the bolt off. at the moment i gave up
>hope, my mothers boyfriend showed up and started
>hitting the head of the bolt with a sledge-hammer and
>then when that didn't work he took the sledge to the
>end of the breaker bar...all the while there was a
>wrench jammed in the hole on the pulley to keep it
>from moving.
>
>somewhere in the mix...a small chunk of the right side
>of the case cracked and fell off (the small piece
>which supports the housing for the front crank seal).
>i could've cried...but i don't cry...i get pissed. my
>mothers boyfriend is now trying to convince me that
>the case can be welded...and i don't know if i should
>accept this or not.
>
>so my question(s) is/are...can these block be welded
>and still be considered structurally sound...and if
>not...does anyone in massachusetts or new england have
>a spare right side case hanging out in thier garage.
>keep in mind i'm pinching pennies now, because i just
>spent a fortune in all the parts for my
>rebuild...anyone have any ideas before i find a cliff
>and jump?
>
>ugh...i hate to say it...but why is it ALWAYS
>difficult...just once i could use some freedom from
>failure...
>
>thanks for the help...
>mike
>
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