Pulley problem

[UK Jack]

Have been trying to remove my pulley as the woodruff keys is worn and there is slack in the pulley and is 'knocking'.

The pulley would not slide off the crankend at all, no matter how much you pushed and pulled. In the end part of the pulley broke so I decided that I would have to cut it off.

The problem I have is that the pulley was sitting behind, I repeat, behind the flange

How the hell I am going to replace the pulley.

I have left the pictures in 'large' format so you can see the problem.

[armydriver]

Is there anyway a pully puller tool will remove it? Is the center of the flange and pully clear all the way to the crankshaft? If so a puller may be the way to go. You might also try heating the flange with a blow torch then when it is hot, try removing it. That is a tough one.

[Corne Lauwerijssen]

Hi

There are (original) pully removers for this job, in the pic above you can
see 2 threaded holes for this job.

Good luck,

Corné

[armydriver]

That is what is so neat about this site. CCKW owners with a lot of expertise always willing to help others when they need it.

[Brent Delaney]

Hi, UK Jack,

There are a couple of pictures that might be of help, these are from TM 10-1449, page 8.9913.

I'm not sure on how to post these directly to this site, so I can send directly to you if needed.
My E-mail address is packman@paradise.net.nz

Cheers,

Brent Delaney.

[Bill_Wolf]

Brent has provided this scan of the pulling tool.



Anybody know where one of these can be found?

Thanks Brent!

Bill

[robc]

It looks like damage has been caused to timing cover?, if you try & remove cover, be aware you will need to remove sump to access 2 bolts which screw into to the cover from the engine side out. You should be able to find a standard puller that will allow bolts to be screwed into the hub and ease it off.
Looks like you need to contact Rex Ward.
Good Luck.

[pfarber]

Spray the bajesus out of it with KROIL. No WD-40, no 3-n-1, but KROIL. Give it a few hours then spray again, repeat.

Now try and remove the pulley.

You could try to use a grinder with a metal cutting disk, then use a hammer/chisel to crack the rest of the pulley.

Heat the pulley CAREFULL THAT GREASE/OIL DOES NOT CATCH FIRE. Like you would a starter gear. You need a MAPP cylinder (no propane, will not get hot enough) or better yet an oxy torch.

After all that, if it still won;t come off, then have a pro do it. They will do basically the same things I just listed, but with much bigger tools.

[UK Jack]

You could try to use a grinder with a metal cutting disk, then use a hammer/chisel to crack the rest of the pulley.

That is rather dim of me, as this would be the easiest and the quickest way forward!

.............I will be back!

[Ledog]

You may also use some TNT.

[Karoshi]

Ah KROIL, cracking stuff, but alas not available in the UK, unless someone can tell me differently.


Karoshi

[Corne Lauwerijssen]

A good pully remover should be enough to do the job. No heating or
penetrating oil is required.

Corné

[armydriver]

make sure you don't cut into shaft with the metal cutting tool.

[pfarber]

Pulley removers operate under the notion that the two surfaces have not joined due to rust or damage.

[armydriver]

You probably have the pulley off by now. If not, put the pulley remover on the pulley, heat the pulley up with a torch, then start putting pressure on the pulley, alternating heating and using the puller.

[UK Jack]

Ok, pullers arrived today so when I got home from the office it was overalls on and straight under the tarp and gave the pulley type thing a pull..........nothing, not a sausage apart from breaking this new bearing puller.

To say that I am close to losing it is an under statement so I decided that I would get the small disk cutter on to it. I cut down, gently and the used a cold chisel to knock it open and lift it off the crank............yeah right, nothing not a sausage thing seem to be part of the crank but the actual pulley bit is an alloy.

What do I do now as I have to move in the next 10 days and I can't leave my truck here, it has to be moved.

I have taken some pictures but they haven't come out well and I am working under a tarp and my camera has no zoom.

Any help would be really really appreciated;

[bobc]

Hi UK, I've been following your problem and it sounds like the pulley may have spun on the crank,which basically means it is now welded to it,I used to work at a shop that did alot of trailer axel repairs,boat people never repack thier bearings so once a week I'd have to try to save an axel,many times I would have to cut the inner race into several pieces then use a cold chiesel to break off the sections,then go back and clean up the shaft with a die grinder and a flat file,it's time consuming but alot cheaper then replacing the axel and in your case the crank shaft. Good luck!

[william mc donald]

hi i hope by now you have the pulley off. all is needed is a puller for harmonic ballancers. it has two bolts that screw into the pulley note the ones with threads on pulley a bigger screw that goes through the puller plate and into the hole in center of harmonic balancer. then just tighten the big screw and off comes the pulley. you may have to tap the pulley shaft if it has been on long. i take them off of equipment that has been setting up many years. bill lenore idaho