I've been reading up on this message board about this problem. I first pulled the hub on partially using the original bolt until it started getting a little harder to torque on. I then went to the threaded rod method. I have an extremely hard threaded rod, hardened washers, and a grade 5 nut trying to force this hub back on. After seriously torquing on this setup, I just popped the threads on either the nut or the threaded rod. I have another piece of threaded rod and another nut, but I figure I will just have the same result. Any suggestions? The only thing I havent tried is applying heat to the hub while trying to push it on...

 

Throw the hub in the oven for a bit, then carry it down carfully and slide 'er on.

 

when i installed mine i didnt realize it was on all the way... needless to say i kept hitting it and i eventually warped it.
point is, it may be on all the way. although it might look like it could go in more. see if it lines up with your other pullies when you put the balancer on!

 

Agreed. When I put mine on it looked like it could go in more, but the pulleys all lined up.

 

You can also put a little oil on the crank snout.

 

Thanks Guys. It May Be On All The Way.. It Looks Like It Could Still Go In A 1/4" Or So Though.. How Much Clearance Should I Have Between One Of The Ears Of The Hub And The Optispark?

 

Not sure about the distance, but the hub goes on until it bottoms on the crank gear.

 

I would advise against applying oil onto the crank snout. That can "air lock" the hub into place (air from inside the hub may not be able to escape while being pushed onto the snout) and can make it even more difficult to install and there is a possibility of damaging/stripping the threads on the bolt and/or crank threads. Just using the crank bolt to push the hub into place dry can tear it up.
You can make your own hub install tool by going to this website. I made one and installing a hub couldn't be more simple.

 

It may be on all the way. Your mind can play tricks on you since the stock one is rusted and you new one (hopefully ) isn't. Just make sure the pulleys line up.

 

Make sure the outside diameter of the crank hub is not rusted. If it is it will chew up the crank seal in no time.

 

You might want to put the bolt in and torque it down. I put the bolt on and got it pretty damn tight with a half inch drive ratchet and it was on all the way. I then got out my 1.5' torque wrench and set it to spec and it still had a lot more turns to go.