After only owning my '93 wrx for just over a month, I was driving kome from the scrappy's with a bootfull of scooby bits I'd just got, I came to a roundabout, went round and put the power on to exit the roundabout when all of a sudden the steering went heavy and the charge light came on. No problem I thought, the belts brocken.So I got home, lifted the bonnet and the belts still there but slack and only half on the pulley? took the belt off and the pulley is wobbling around on the shaft? so I took the pulley off and the back of the pulley is worn away so much the keyway is gone. Then I looked at the sprocket and the same has happened to the sprocket and the crankshaft!
The key has just eaten away the whole thing. I think that when the T.B. was last changed they lost the woodruff key and just used a mild steel one. Now the sprocket has pretty much welded itself to the crank but the keyway in the crank is a big gaping whole so if I did manage to take the sprocket off I'd never get another one to stay put. I've got another pulley and did think about drilling two holes in it and pinning it to the two holes in the sprocket but thats going to put all the pressure from all the belts on whats left of the key and if that slips bang goes engine! Anyone got any other ideas or is it simply save up for a new engine time... I dunno?