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Old 10-16-2015, 10:35 PM   #11
Aqua Puttana
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Default Re: 2004 Sprinter crank bolt snapped while on 101 fwy.

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Originally Posted by stoney500 View Post
...
My best guess is game over.
First. I haven't seen the damage.

How much do like to roll the dice?

The key is an index. Once the assembly is properly torqued into submission the key really shouldn't see much stress. when the assembly remains properly tight there is no movement against the key assembly or else the metal will fret... like your's did.

JB Weld and some other repair epoxies have done some amazing things. Some are very machinable in that parts can be reshaped by patiently using a hand file.

Of course there is some risk, but at what I pay myself per hour I have made some successful repairs which I would never do as a professional.

Good luck.

vic
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Old 10-16-2015, 11:19 PM   #12
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Default Re: 2004 Sprinter crank bolt snapped while on 101 fwy.

I just happened to see this thread. I am not familiar yet with the sprinter balancer and crankshaft, I have used the metal mending products to repair other crank keyways with success. Even keyways that drive the camshaft belts.
Get a new key, clean the crank and balancer as much as possible. One side of the slot is usually still in good condition, use that as your alignment. Fill the other side with your choice of repair compound and assemble the parts.
Probably should lube the threads and underside of the bolt head. have the crank locked up at the flexplate end and torgue to spec. Doesn't sound like you should use any Loctite type compounds for this torque procedure.
Let it set for 24hrs, or as recommended for compounds used. I think it is Dexron that I like myself. Something like that.
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Old 10-17-2015, 12:46 AM   #13
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Default Re: 2004 Sprinter crank bolt snapped while on 101 fwy.

This is not a game-over. 5 degrees is really not that bad and as others have pointed out it is possible to repair it. If you have been able to remove the key then I imagine that there are actually two keys used in this engine. One for the cam-drive sprocket and one for the damper pulley. Can you tell whether or not the key also engages with the sprocket?

The damper pulley is rarely a 'timed' assembly so if it it off by a few degrees it will be unlikely to have any negative repercussions. The sprocket on the other hand is of-course sensitive to timing, but 5 degrees is definitely not enough to cause valve interference and the effect it could have on performance is probably negligible. With a new key and a new damper pulley you may find that the amount of slop decreases, since some of that is coming from the deformed key and keyway in the pulley.

If it were me, I'd goop up the keyway in the crank with some 2-part epoxy, drop the key in and then slide the pulley on. Feel the slack in the joint and try to find the middle of that. Let the epoxy cure briefly and then remove the pulley without moving the key, clean up any excess and then let it cure fully before throwing the pulley back on and cranking it in. Turn the crankshaft until the keyway is facing up before doing any of this so that the epoxy doesn't run out and so that the key isn't being pulled in one direction or another.

You can apply some grease or vaseline to the keyway on the pulley to keep the epoxy from joining with it. You should also reserve some of the mixed epoxy so that you can test that to determine when it's cured enough to be able to remove the damper without moving the key.
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Old 10-17-2015, 08:18 PM   #14
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Default Re: 2004 Sprinter crank bolt snapped while on 101 fwy.

Ordered new front seal,new crank bolt, new balancer alignment key and now looking for crankshaft lock tool to buy or borrow or rent. Parts should be in Tuesday a.m.
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Old 10-17-2015, 10:24 PM   #15
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Default Re: 2004 Sprinter crank bolt snapped while on 101 fwy.

stoney500,
You're not going to replace the harmonic balancer?
I'd be darned sure the inside bore of the HB was "perfect".
Right on size, no scars, smooth ground finish, perfect keyway.
Or did you miss a comma above and mean a new HB and new HB alignment key?
The more "on size and to spec the bore in the HB is the more reliable (in the long
term) your repair will be.
Roger
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Old 10-19-2015, 09:25 PM   #16
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Default Re: 2004 Sprinter crank bolt snapped while on 101 fwy.

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Originally Posted by autostaretx View Post
The 2004 bolt was originally listed as (dodge) 05073696AA
The washer under the head is (dodge) 05080005AA

--dick
Thanks Dick,

Ordered one from Local dodge dealer this morning. should be here tomorrow. Freightliner dealer said 3 days.
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Old 10-23-2015, 02:12 AM   #17
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Default Re: 2004 Sprinter crank bolt snapped while on 101 fwy.

Ok, I spent 400.00 more and bought a new oem HB. I have the extra a/c so I had to get the HB with the added v-belt pulley. Now I need to lock the crankshaft and need to torque Crank bolt to 240 ft lbs + 90 deg. Anyone in the san fernando valley/ Simi valley area want to rent their om647 crankshaft locking tool? I'm happy to leave a deposit.
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Old 10-23-2015, 07:47 PM   #18
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Default Re: 2004 Sprinter crank bolt snapped while on 101 fwy.

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Originally Posted by stoney500 View Post
Ok, I spent 400.00 more and bought a new oem HB. I have the extra a/c so I had to get the HB with the added v-belt pulley. Now I need to lock the crankshaft and need to torque Crank bolt to 240 ft lbs + 90 deg. Anyone in the san fernando valley/ Simi valley area want to rent their om647 crankshaft locking tool? I'm happy to leave a deposit.
Why don't you just buy one Mercedes Benz Flywheel Locking Tool $19.99 +Freight



Or this kit off of Amazon Supercrazy Mercedes Benz Chrysler Jeep Engine Camshaft Alignment Locking Timing Tool Kit SF0102 $63.99 & FREE Shipping

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Last edited by PATECO; 10-23-2015 at 08:00 PM.
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Old 10-23-2015, 07:58 PM   #19
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Default Re: 2004 Sprinter crank bolt snapped while on 101 fwy.

Got my Bolt yesterday looking to do the replacement tomorrow afternoon
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Old 10-24-2015, 09:54 PM   #20
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Default Re: 2004 Sprinter crank bolt snapped while on 101 fwy.

I already ordered the crank lock tool, it should be here today
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