KC-
Have you stood both balancers next to each other to verify they are the same depth (from the pulley mounting face to the end of the shaft)?
TJR-
Actually, if I'm understanding you correctly, yes, the method you used to remove the balancer bolt could have done some damage, but I doubt it. For future reference, the simplest and safest way to loosen the balancer bolt is as follows: assemble a 1/2" drive breaker bar, 4" extension, and the proper size socket, and put it on the balancer bolt so the breaker bar handle rests on the ground, on the battery side. Disable the ignition system (disconnect the coil), and bump the starter with the key. This works on every type of vehicle I know of, except for Honda's. Their engines rotate backwards (counterclockwise).
Mach 1 is right in that you really should have torn this back down when you realized the balancer was sticking out farther. Then you could compare crank gear thickness.
Remove the balancer. Use a depth gauge, or a narrow aluminum ruler, and measure the distance from the crank gear to the edge of the seal lip, along the snout. Now measure the balancer shaft from the end to the wear mark. If the measurements are the same, the balancer is binding and isn't seating against the gear. If the measurement is different, then the crank gear is fatter than the previous one, and you need to buy an appropriate balancer that is slightly shorter.
Take care
~Chris
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