Vibration damper / crankshaft alignment

Well, I found out what was chewing our alternator belts...

the lower pulley wasn't lined up - so we tried tightening it, but couldn't get it tight... that's right, pulled it off and it's no longer lined up properly to the crankshaft...


The little notch on the crankshaft is pretty chewed - the pulley looks fine, but I'm not confident it will 'hold' the vibration damper in place properly - and if it moves at all, it could run right off. : (

This also explains my timing issue - the pulley really was 'walking' : )

Anyone have any experience with this? Any clue how to fix it... I'm afraid to just press it on...

oh yeah, it's a 3vze engine on a 94 4wd.

local toy dealership is telling me that this notch is replaceable, and it's called a woodruff key - does that sound right? The notch I'm thinking didn't look like it would just pull out... but there was a rectagle hole in the shaft (that looks like it could match the rectangle channel in the pulley). But it's about 1/8 turn from the notch that appears to be chewed...

Any one ever had to replace this? Do I pull the oil seal?

The woodruff key just fits into the slot on the shaft. It should come out without much trouble and without removing anything internal to the engine. If the key or the slots are worn, it will allow movement.