A buddy down the road a ways, decided to pull his crank gear with an ODD-O ZONE set. he has the crank gear about 1/4 inch off now. Problem is, it seem the puller ate the threads right out of the crank! I was not around so I don't know what really happened, but I assume he just overtightened the puller, until the tip ate into the inside of the crank (where the balancer bolt goes). There is about 1/2- 3/4 of an inch of thread left way up in there, but Im afraid the damage is too much! I am not a machinist, so I am probably not much help to him. This guy has no $$, and if we cant get this fixed up, his project is at a standstill. Any Ideas????? Thnx for any help.

Get a bottom tap and run the threads. The remaining threads will probably do the job with a stud in place of the original bolt. Thread a bolt in all the way and pull the gear with a standard puller on the bolt head.

We'll give it a try

If the bottom tap don't work.... Try a heilcoil set. Drill hole out to size they tell you, then install the helicoil into the drilled out hole.. Then you can re use the std. damper bolt.

Not all pullers are created equal and maybe hard to find one that has the right features. This is the set I own and use it for harmonic balancers and steering wheels. Tip A is dished in and is what was needed to prevent the problem this thread is about. Tips B are your common pointy type that caused the damage.

http://micbun.freehostia.com/files/puller.jpg

Well If I understand ttopbandit's post right, then it wasnt the damper his buddy was trying to pull off. It was the lower timing gear on the crankshaft..

If that's it, then the damper/wheel puller posted above wouldnt have done him any good.

When pulling the Damper or lower gear always thread the damper bolt back in without the washer. Lightly bottom it out then use the puller against the bolt.
To repair chase the threads with a chaser not a tap then stud it. A tap will make the remaning threads sharper and weaker.

Also, after all above is done, get a grade 8 bolt that is a little longer than the one he removed from the crank pulley, I did the same and used a slightly longer bolt to help out.

I put "Tip-B" on the center of the bolt-head and go!!

And of course remove the thick washer and pulley(s) first....

pdq67

Thanks alot. Plenty of great ideas. I have to buy a "chaser" now, since I seem to have the "community tool box", haha. Anyhow, thanks for all the great suggestions.