BHW Crankshaft Sprocket Broke

GoremanX

Veteran Member
Joined
Mar 17, 2013
Location
Vermont
TDI
2001 Audi A4 Avant quattro w/BHW TDI & 01E 6-speed
While trying to pull the crankshaft sprocket off (for a balance shaft delete), it shattered. I was using the right tool and method, but it still snapped in 2 :(

The crank is installed in the block with all new bearings and main cap bolts that are fully tightened down. I wasn't expecting the sprocket to break since I was using the appropriate tool for the job.

So what's the best and safest way to get the rest of it off? Half the sprocket and all of its hub are still sitting on there.
 

GoremanX

Veteran Member
Joined
Mar 17, 2013
Location
Vermont
TDI
2001 Audi A4 Avant quattro w/BHW TDI & 01E 6-speed
Nevermind, I figured out a way.

First I taped up the block and main cap around the crank snout to prevent debris from getting into the bearing.

Then I used a Dremel with a cutoff wheel to cut most of the way through the hub.

Finally I used a flathead screwdriver and gently tapped it into the Dremeled groove until the hub snapped.

With the hub cracked and the screwdriver wedged in, the sprocket was just loose enough to slide off the crank snout without resistance. There was no damage done to any component.
 
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