Just finished replacing the damper in my M1009. A lot of great tips and info via search. I'll take a crack at rolling some of them up and adding a few of my own. Remember, I'm not a professional mechanic so use your own judgment. YMMV.
Removal:
- I removed the belts, fan and pulley, and fan shroud.
- Before removing the belts, loosen the nuts on the fan clutch/water pump pulley 1/4 turn. Don't remove them yet, just loosen them a bit. This is easier to do with the belts holding the pulley for you.
- Others suggested covering the radiator with cardboard. I used a piece of masonite. The quality of the protection should match the size of the klutz. I'm a pretty big klutz. Given the expense and PIA factor associated with a radiator repair/replace, this is cheep insurance.
- I have the good fortune to have an impact wrench to ease crank bolt removal. If you go with the pry bar method, then radiator protection is a must. Also, I would try it with longer bolts than the stock ones you just removed.
- Got a puller from Craftsman. Not pimping Sears, just saying it worked nice at $17-18. Did have to get a few M10-1.50 x 75 bolts and washers though. There were none in the kit that fit our damper. These bolts worked fine with the Craftsman puller.
- You have to pull the damper just over 1" before it clears the oil seal. One might consider stopping just short of that for some cleanup in the oil seal area with a scraper, toothbrush, and/or air. The more dirt removed at this stage, the less to deal with during seal replacement.
- Personally, I wouldn't consider replacing the damper without replacing a 25 year old seal. They are cheap.
- Be sure to account for the spring in the oil seal. It should come out with the seal. Make sure. You don't want that in your crankcase.
- The old seal left some residue on the timing cover. Some brake cleaner sprayed onto a rag with elbow grease took care of that. I would not spray cleaner directly onto the cover lest it enter the engine, but that's just me.
Install:
- The PVC fitting section of your building products store is a treasure trove for seal drivers. PVC unions in particular have a lot of nice parts of various sizes that can be used as drivers.
- Personally, I would never use a hammer on my crank. You can manufacture the tool referenced in the Fluidampr article. However, keystonebuilder70001 suggested a M16-1.5 x 100mm bolt. That with a nut, washer(s), and a couple of wrenches made a great installer. My Fastenal didn't stock this bolt so deal with it ahead of time if you are looking for a one day project. (Thanks keystonebuilder70001. That was a great tip.)
- Used anti-seize in lieu of grease on the shaft and bolt.
- I didn't have a friend (available) to hold the fly wheel so I drilled a hole in a piece of steel bar and bolted it to the damper. (See picture.) This rested against the bottom of the right front spring, making the final torque pretty easy. Since it was bolted to the damper, I didn't have to hold it.
- I also used a single drop of blue thread locker on each bolt on the main pulley. Probably overkill.
Attached a picture of the back of my old damper to show just what bad shape the rubber ring was in.
Went with the FLuidampr. Wish I had taken before and after video. It runs noticeably smoother now, quieter, less vibration. Happy so far.