I can't fathom how you can discover "true" TDC with the piston stop and your timing pointer, and when you turn the crank to "true" TDC...the single-keyway crank gear can't line up with the cam gear. This indicates problems that are so unlikely as to be ridiculous.
Yes this is my conundrum.....I FULLY understand the piston stop process of finding exact TDC...... and I feel (or felt) confident that my mark was actually just that.....
From my very limited knowledge, but more from just common sense, I am 100%with you in not being able to fathom how it would even be possible for that crank gear to be off.....
I mean you have the two reference points for piston travel limit in opposite directions of crank rotation, you have the centerline of those two reference points as a third reference point which is, by mathematical and geometrical constraints, NECESSARILY EXACT TDC......(as long as my process was kosher)....
what in hades could allow crank sprocket to be out of alignment is something I'm sure I don't want to know....
I've been focused on the "error" of TDC marking on the damper; and it seems to potentially be a mis-matched damper/tiiming pointer.
I'm not sure that's the case....I did think so until I checked the damper I pulled from the pull a part and its keyway and factory timing groove are located identically to the one on my truck..... and like I said the timing cover is almost certainly original to the truck (made in Canada) with zero evidence of any modification anywhere on it......
I'm now wondering if the error is with the piston-stop and finding "true" TDC. Do the crank and cam alignment marks line-up when the factory mark on the damper aligns with the "0" on the timing pointer?
Yes I'm second guessing myself as well and am going to redo it and see if anything changes or pops out to me.... and yes if you look at the last 2 pics I posted, it does appear that were I to put the factory mark at 0°, the crank would be able to align with the cam at proper up and down orientation...... the two TDC marks on damper (mine and factory) appear to be off
by about the same degree of offset as the crank gear is from being vertical.....
Man thank you so much for your patience and willingness to help