I have a 96 vortec 350 that I'm building. I'm using a 92 350 serpentine belt system as well as the balancer. I'm having issues getting the balancer seated all the way. I rented a install tool and it still needs to go in about .150 to line up with the rest of the pulleys. So I decided to give it a little more umph and snaped the install tool. I was lucky to get it out of the crank. Do I need a 96 balancer? My plan is to take the balancer and gently sand it with some 600 grit then, put it in the oven @ about 200 deg. and then try to install it. The 96 crate engine I got had two keys in it end to end. Is that normal?

 

It sounds like everything you are describing is normal. I had to use a rubber mallet to get mine seated all of the way, when the install tool was no longer effective. Most will tell you not to use a rubber mallet and I completely agree with them but it was the only way I could get mine seated.

As for the two keys end to end, I cannot comment as I do not quite remember. However, I only recall there being one key.

 

Doesn't the Vortec motor have a "tone ring" inside the timing cover for the crank position sensor to read off of that's about .100" thick?

Might want to take your 92 balacer down to the auto parts place with you and compare the length vs. a 96 Vortec balancer.

 

I dont know. I'm using my stock timing cover from a 92 on the 96

 

the part # for a 96 truck balancer is different than a 92 truck balancer

 

Make sure your timing chain sprocket is set all the way. You might have to get a block of wood to get it on.

 

Is the reluctor ring behind the timing gear? If so and I didn't remove it,and tried to put on the 92 dampner, which I found out is about .150 longer than the 96 due to the reluctor ring. It might be the problem???? Would a crate motor come with a new reluctor ring on it?

 

A universal replacement crate motor (for general use in many applications) probably would not come with one, but I don't buy crate motors very often so I couldn't say for sure.

If it's an original Vortec truck motor it's definitely got one to run the crank position sensor, obviously.

The ring goes on the OUTSIDE of the crank gear.

Sounds liek this is almost certainly the source of your problem.