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Crank pulley loosens itself from crank, but why? 900 1994

posted by  Volvo945 on  Sun Jan 8 13:39 CST 2012
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last visit: Sat Oct 12 15:05 CST 2013
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Before you answer with the obvious response "because it wasn't torqued correctly", here are some facts. I replaced the head 9 months ago so the pulley was installed at that time. Since then the car has had about 2,000 miles put on it. I'm certain we followed the specs on the crank bolt torque (44 ft-lbs + 60 degrees). The drive pulleys spin freely (water and PS pumps, alternator, A/C), so I don't believe anything seized up to cause this.

The problem happened when I started the car after it had been sitting for only 24 hours. Heard some metal screeching and popped the hood to see the motor running but not the crank pulley. The crank bolt was loose and almost free. I could pull the crank pulley straight off with belts attached. The key is missing.

So what did I do wrong? Can the key fail spontaneously like that? If it was a torquing issue, how did it go this long without some warnings of impending failure?

Thanks for the advice.

--
'94 945t; '94 944t; '05 S80 2.5t; '01 S40t






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