Crankshaft sprocket won't fit

Hi guys, 

I'm new to the sight, great information here.. thank you. 
I'm rebuilding a 2.3L Lima out of a 88 TC. The problem I'm having, I had to remove the crankshaft sprocket to get at the front seal. That was a chore in itself, I tried heating it, I tried two versions of a homemade puller. Finally had to drill and tap the sprocket and try to use an "H" puller to pull it off the crankshaft. That ended up snapping the sprocket in half. So I replaced the seal, ordered a new sprocket, tried to slide it on only to find it was too small for the crankshaft by just a touch. I tried heating the sprocket, not red hot but pretty hot and still could not slide it over the crankshaft. I have two more sprockets coming from an 88 2.3L out of TCs. I pray one of those will slide on. I saw where others had only to slide them on no problem. Have you heard of this before, a crank sprocket not fitting the Crankshaft? It's like the Crankshaft is the wrong size. When putting new rod bearings on the crank, everything went together well. I plasti gauged everything, I was on the tight side of standard but everything fit well......... Any suggestions?

Thanks,

Harl

Oh Man, that is unusual for sure. I have never rebuilt an engine that had a crank sprocket that was that tight. To remove, I simply used a puller and they popped right off and install was straight forward as well. Could you have a machine shop check the crank for trueness? I know you already put it together, or have them trim out very little from the sprocket? Do you have a micrometer to take some measurements on the crank and the sprocket to compare?

Kuch, thanks for the reply.. I received another crank sprocket with the same bore, it's to smallfor the crank by the same amount. This engine was a basket case with parts from a 2.3 Ranger non turbo mixed in. The block and head were bolted together. I'm wondering if he used the crank from another engine. Seals and bearings went in fine. The block is a turbo block with the oil return hole on the passenger side. I'll measure the crank and take one of the two spares to have the bore enlarged. I thought I might heat it cherry red and try it again. But everything I've seen and heard, the crank sprocket should slide on without much effort as the other two did. First time with a 2.3Lima I'm on a pretty steep learning curve here. Once the crank sprocket's on, I'll drop the engine in the vehicle just get it out of the shop. I have a 3.0L to put in a Ranger and a clutch to replace in a 97 Probe GT. Nice sports GT car...

Man, I would hate to have to heat up a sprocket to get it on there, but if you have to do it. I bet your right and they used an older 2.3 crank in there. Also agree on the Probe GT, I had a 94 GT many years ago and it was a fun car to drive. I still have to 16" GT wheels in the garage.