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...I got my new pulley. Then I noticed lots of small pits in the area where the pulley meets the seal. I needed to use 320 grit to get most of them off, followed by 600 grit. Now almost a mirror finish.
There are tiny pits left(well one pit), but I am afraid of removing too much material and screwing up the seal. All the old wear marks and pits are gone. I have no leak anymore, and the pit I left was so small that I almost couldn't catch it with my fingernail. I am hoping that the rubber seal also has no problems here, especially with oil acting as a lubricant.
I then lightly sanded the inside of the pulley so it would fit on the crank without a problem. I used a screwdriver to remove rust in the woodruff key area. I then used high temp anti-seize in the area that goes over the crank. I also used antiseize on the bolt that secures the pulley. Everything snugged up easily and properly. If I need to pull things apart, the anti-seize will prevent issues.
One needs to really be careful when swapping pulleys. That outer circle of metal that contacts the forward gear cover seal needs to be carefully evaluated.
One also needs to be carefull to line up the woodruff key. I though I had lined it up properly with the broken pulley, but I did not sand the inside of the other pulley, it was a hard fit, and it is a possibility that I did not line it up well. The new pulley with the sanding to get rid of inner rust allowed the pulley to slide on and be rotated until the pulley positively caught the key. That positive tactile feedback is critical.
Best,
C
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