what we do in this case is to take locktite Quick metal all around the key
and  a center punch and pinch a new woodruff key on the sides. then torque
the bolt on using blue locktite.  I would recommend changing the seal and o
 ring before doing this.  We have done this to a number of cars like
subies,  toytotas and old VW buses also  later  mark d

In a message dated 9/11/2011 1:35:26 P.M. Eastern Daylight Time,
wognacious@GMAIL.COM writes:

My  girlfriend has been driving my vanagon pretty much daily. Recently she
said  that she thought something wasn't right back in the engine
compartment.
Well she was right, the bolt that's supposed to hold the  pulley in place
had
worked itself part of the way out. Upon further  investigation I discovered
that the woodruff key was not in the slot, or  what's left of it. It was
kind
of in there on it's side and the slot is no  longer a slot it's bigger than
it should be. One side is square but the  other side is not good. I don't
have the time or $$ to pull the engine out  to replace the crank so I'm
trying to fix it the best I can and hope it  will hold up for awhile. Has
anyone had this problem and if so what did you  do? I've considered trying
to
drill a hole through the pulley and into the  crankshaft, tap it and run a
allen bolt/screw in to keep the pulley in  place. Maybe make the existing
slot larger and make a bigger key.
Any  help or insight would be greatly appreciated as I need to get the rig
back  on the road.
TIA,
Paul
85 WWW,  1.9L