Woodruff Key Replacement

Long story short; had to decide between full engine rebuild or getting a rebuilt engine. Chose the second option (and yes feeling like that was a mistake, but I digress) and had a local shop do the swap cause I had no time.

Well the front seal started to leak and when I pulled the crankshaft pulley, it was cracked on the back side. Looks like the garage forced it on. Well now the new pulley won’t fit cause the Woodruff key is damaged. Am I seeing this correctly and will need to remove the crankshaft timing gear to fix what the garage messed up?

Also, are there any similar woodruff keys that fit in the crankshaft that could explain why the one on the shaft now is taller than the crankshaft pulley would allow?

 

If done correctly those ate tight enough that I've had to GENTLY tap them into the crankshaft slot with a brass hammer.
The key itself may be " rocked" in its slot. The outer flat of the key should be parallel with the long axis of the crank.
Id try tapping the "high side" to see if it will move back into place.
Good luck!

 

Thanks for the help. When I tapped it back into place saw a crack and now have to remove the gear.

On another note; is it common to have a new timing chain tensioner #1 extended almost 3/4”? Seems like their was a failure and with a new chain can’t think this is a stretched chain...