crank timing gear... wow, what a bear.

[bugnut68]

Okay, I barely got my old brass distributor gear off without going ape nuts on it.  I heated the holy snot out of it for what seemed like an eternity before I finally got it off of there, but the cam timing gear is absolutely not coming loose.  It's so snug that I wonder if a gear puller will be any easier.  I aim to buy a gear puller regardless, but I figured I'd try it this way to begin with.

Anybody have any insider knowledge that might help me out?  The gears are coming off what appears to be a cheap cast crank, so I'm wondering if the tolerances are different or something.

Also, regarding woodruff keys, is there any difference between the keys sold by VW parts houses and what's available at the local hardware store?  Trying to save shipping if at all possible, but if there's a serious material quality difference then I will wait until my next mail order purchase.

[Bruce]

You can't get the cam gear off with heat.  The crank's diameter increases just as fast as the gear, so the interference fit remains constant.  You MUST use a gear puller.
It is unlikely your local hardware store will have a metric key.  Order one with your puller.  What's wrong with the one in the crank?

For future reference, any time you use the gear puller, REMOVE THE CLIP!!!

[Type1/DVK]

Get a quality gear puller, and use original german keys. 

[besserwisser]

About ten years ago I made a tool for removing the gears on the crankshaft. Its two halves that fit under the timinggear and reinforced by thicker metal around the bearing next to the timinggear. I use  my regular press to get the gear of and so far it has removed about 100 gears but is showing some wear. Will probably have to make a new one during this year. The cost is next to nothing so maybe I will post a drawing of it later.

[bugnut68]

You can't get the cam gear off with heat.  The crank's diameter increases just as fast as the gear, so the interference fit remains constant.  You MUST use a gear puller.
It is unlikely your local hardware store will have a metric key.  Order one with your puller.  What's wrong with the one in the crank?

For future reference, any time you use the gear puller, REMOVE THE CLIP!!!

I was thinking about that as I was making my attempt, Bruce.  I couldn't help but wonder how it could possibly work if the crank was also expanding with heat, lol, thanks for confirming my curiosity.  I've been planning to buy a crank gear puller, anyway, as that's about the only VW engine tool I don't have at this point.  I may just wait to get it and then use the key that's in this crank that still has the gear still on it.

[Bruce]

The reason you were able to get the dist drive gear off is because brass expands at about 3 times the rate of steel.  IOW, get them both hot enough, the brass gear will be loose. 

[Jim Ratto]

which key do you  need Ryan? I will mail you one,
Jim

[bugnut68]

which key do you  need Ryan? I will mail you one,
Jim

It's the larger one for the cam timing gear, rearmost on the crank, not the one on the nose of the crank, if that makes any sense. 

[Jim Ratto]

pm me your address.