[s-cars] sheared crankshaft-gear key

[Theodore Chen]

the crank seal is a piece of cake to remove with the factory tool.  it was so easy to do, in fact, that i didn't remember doing it until somebody posted a picture of the tool to the list.




________________________________
From: Paul Heneghan <paul at heneghan.co.uk>
To: s-car-list at audifans.com
Sent: Thursday, January 22, 2009 5:17:39 PM
Subject: Re: [s-cars] sheared crankshaft-gear key

Just adding in some data from the other side of the pond.

Did my first i5 t-belt without the 2084 tool.  Job was difficult, but
successful.

Bought another i5 car a couple of years later.  As I had no time, I got a
local Audi garage to do the t-belt.  Six months later, the car lost all
power and I found that the valve timing was wrong.  Assuming the t-belt had
jumped a tooth, I fixed the timing, and a day later, it lost power again.
Then I discovered that the timing marks on the flywheel and the crank pulley
didn't agree.  Started to undo the crank gear bolt and was surprised that I
could undo it with a short-armed ratchet.  Discovered that there was no key
left on the crank, just a little bit of metal powder.  The Audi garage had
presumably reused the crank, bolt, used no sealant, and not used enough
torque.  As six months and 8,000 miles had passed, it was pointless taking
it up with the garage, but from then on (early 90s), I have done all my own
car maintenance.

Now I've got my own 2084 (three successful t-belt jobs done with it), and
recently I've bought the 3256 for the AAN.  I've got a brand new crank gear
and bolt ready to install along with the t-belt as soon as the weather gets
warmer.

I also think like Dave Lawson when it comes to assessing the cost of
insurance against the cost of not having insurance, but as I have two AANs
with unknown previous history, and personal experience of a failed crank
gear key, the right answer for me is to have a new gear (GBP30) standing by
in case it's needed, and always replace the (stretch) bolt (GBP10).

I still haven't made up my mind about the crank seal or the CPS.  Seeing as
both cars have done close to 150K miles, I'll probably replace them - I've
already bought them just in case.  I'm put off by accounts of the seal being
glued in place, and near impossible to get out cleanly.

Paul
1995 S6 Avant
1996 S6

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