Crank Gear Key <VS> Replace Short Block

[mindshot08]

So I towed my '99 Sportage 2wheel drive to the Kia Dealership because the car wouldnt start, it would turn over, but just couldnt get rotating enough to stay running when you let go of the key and clutch.
Turns out it was the wiring harness (recalled in '98 to '01 models) and it was repaired for free.

But the car was still running poorly and I authorized they to rob me of $90.00 an hour for a diagnosis. They returned saying that the problem is the "Crank Gear Key" and the only way to fix that would be to replace the short block at a cost to me of over $5,000.00. I kid you not.

At this point I have called several other mechanics just to find out that the crank gear key is not something that should have ever broke with out manipulation or poor manufacturing. And I also learned that replacing the short block is not nesessary, it is a simple bore and re-weld procedure, with the possibility of having to replace the crank gear depending on the damage.

Has anyone experianced this?

Should Kia be responsible for fixing their error?

Am I better off spending the $5000 i dont have on a different non-kia car?

[sportage4x4]

$5000 is not out of line to replace the short block. however, i doubt very much it has to be replaced. the only situation where the short block may be replaced is if the crank nose is so very badly damaged that it cannot be repaired. in that case, it is smarter to replace the short block, versus replacing just the crank.

this is not a common problem, but it plagues some other mazda engines as well, not just the FE3 in the sportage. the early B6-DOHC engine suffers the same problem.

9 times out of 10, you can just replace the key, and use a loctite bearing/sleeve retainer on the gear, let it fully cure, then reassemble, ensuring 100% proper torque on the crank bolt.

search the web for 1990 miata crank gear key problems, you will see the problem, and the solution.

[ron1004]

Here's a thread which you'll find interesting.

It has links to the in situ Locktite fix.

http://www.kia-forums.com/2g-1998-20...e-right-4.html

[edselsouth1]

This problem is not a very common problem, but can occur in any make of vehicle. At present we have a Nissan Pathfinder with a sheared crankshaft key (95 cents @ the dealer), but no damage to the crank itself. We have also had a similar problem on a Mitsubishi Montero.This repair took a bit more work time, and some dealer parts, but was also successful. I've seen it on a 351-C Ford engine, as well as the nose of the crankshaft sheared off on a 351-C Ford engine. All of the above were able to be repaired at a reasonable cost without replacement of the short block. Have the repair done right the first time or you will have more troubles in the future.

[tonup]

I make it clear from the start, I have never operated on the sport engine, but in my experience these keys usually break when the bolt or nut has not been tightened properly.
usually you just replace the key for a buck or 2 or 95c as mentioned above,but it is essential you carefully inspect the new key when fitted in the keyway because a loose key can wear the keyway, and a new key may not be tight enough, they must be a snug if not interference fit.
I have had a loose key break the nose of the crank, needing a new crank, but I doubt very much that a new block would be need and unless it includes the crank there would be no point. in any case a new crank would do the job, or if it is loose just take the crank to a machine shop and they can machine out the groove to an oversize key, if kia don't do an oversize key there are many aftermarket makers who will have one that fits, but before going to the bother of pulling the engine and stripping the crank out try buying an oversize key, say 1thou and 2 thou, might do the job, but if the keyway is mutilated you should get it done properly.