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UPDATE: Ok, it's been about 300-350 miles since the repair. Yes, I drive this truck a lot. Still smooth. I paint marked the bolt in relation to the washer, the washer in relation to the pulley and the bolt in relation to the pulley, using a large "X" with all lines pointing to the four...

UPDATE: Ok, I reassembled everything and WHAT A DIFFERENCE. SMOOTH AS SILK. FASTER, MUCH MORE RESPONSIVE. The truck runs like a new truck. I did some research and the poster above was right, this was very common in the 6.2 GM civilian trucks. According to GM, the problem lies within the...

I'm sorry I completely missed your post. Any leads or help would be appreciated!

Again, I agree your approach is the right one, should I want to keep the engine. I checked all day yesterday with machine shops and welders, even showing them your post to see if they can do the work. All denied. I even went to the neighboring towns and nobody will touch it without removing...

So, here's my plan: I'm picking up the new engine this week - a low mileage 6.5 with all the accessories already on it. I'm going to order all of the maintenance items on this "new" engine - new belt, hoses, balancer, glow plugs, PCV, various sensors, and maybe a water pump and fan clutch. I...

But drilling a dowel would require also carving a channel to accept the dowel in the balancer and I'm just not skilled enough for that. I do agree that your suggestion would work, however. I also plan on loading it up with Loctite when I install the balancer, hopefully to make it more...

So, I attempted a repair with JB Weld hi-temp steel paste. This is only to get me out of the garage and into a qualified shop for the engine swap. I am still installing the new OEM balancer, pulley, and new crank bolt.

I agree it's an easy swap, but in Florida (the sunny place for shady people) I'm getting $10,000 labor quotes and that's if I supply the engine.

So I started a new thread to illuminate the importance of checking "shake" in Humvees. This was my first so I assumed it was normal. I removed my crank pulley and harmonic balancer this weekend, which by the way was a beeotch. Once removed I noticed the key channel was intact only toward the...