"You want the truth?....

You can't handle the truth"...
...

Honestly,... once it has some wear. it will continue to wear, due to the ability to now move forward and back on accel and decel...
.. like a little jackhammer every start and stop...

I think Oldfeller has tried some JBWeld in the splines... (somebody did)... Never heard if it worked...

At least... put some locktite on it and be alert for the loose sound...

Mine was loosening every 6 months of so... 'till I bought a new washer, tightened it with an impact wrench, and used locktite... it's been quiet for over a year now...
There's no good fix, that I know of... just keep it tight.. and hope for the best...

That's for you to decide,.. based on your experience...
New spline shaft, pulley, plus gaskets will cost a $100 or $200...
... and you might booger the assembly (I would)...

I would never attempt it... if mine goes, I'll locate a low mile engine and start over with newer everything...

JMHO... I'd make it super tight and keep an eye out... if the splines wear too much, have it welded in place...(you'll never be able to get the belt off from that point, but it can last 100k miles)...
Then, when the belt finally goes, just buy a new engine...
It ain't the right thing... it's just what I'd do...
...

PS.. I can't remember if you have to remove the pulley to replace the stator...
Anybody?...

PSS.. actually,.. you could replace the belt,... by grinding away about 30% of the outer pulley edge... just enough to get the belt past the stator cover case... not sure if that would be too much to keep the belt in place for use... but it might stay... might be fine...

There was someone on here that tried to replace the output shaft once.
She was a newb to the savage, but game enough to try, so musta had some skills.
Don't know if she picked up the wrong shaft thru incompetence of the seller or just inscrutable mods to the tranny to make most years incompatible with others.  but the one she got didn't fit the one she had.
The last I recall OF doing was a RTV filler, I don't think anyone has done a proper JBweld fill.  You'd have to have a pretty bad gap for jbweld to work.  and getting it in there consistently aint gonna be easy.  and won't be any more removable then welding.  I'd want to pressure feed it into the splines.  My thought was to grind a groove in the middle of the gear cutting thru all the splines of the pulley.  then drill and tap a hole from the outside to the groove.  slip the pulley on the shaft, fill the hole with JB and force it with a bolt into the pulley till it shot out the splines.  Put the nut on tighten as required.  To get it off, use a torch to burn out the JBweld.

I haven't had first hand experience with this particular engine but.... most pulleys are made of a milder steel than the shaft.  If the majority of the wear is in the pulley, I would buy a new pulley. This may take care of your problem.  As for the photo, not as clear as I'd like to see it but from what I could see, it didn't look bad.

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I second Steve H. My Clymers says that the pulley has to come off, but when I polished and re-clearcoated the stator cover on my '06 I got it off without touching the pulley with no problem.

OK two more quick questions... Should I replace the can chain tensioner slides when I do the new chain or reuse em? And when I took the head off the gasket was two metallic pieces...what's that about?

Eh I am replacing the chain now cuz its well stretched, and I'm talking about the gasket itselfnwas metal with guest between em.