Hi all,
I am having to replace the crank pulley and woodruff key but am having a complete nightmare removing the second part of the pulley. The woodruff key is badly damaged so is impossible to remove from the crank without getting the last pulley off. The key was at an angle so we have cut the edge off to try and get the pulley off the crank. But no matter what we have tried the pulley will not budge. It feels like it is seized on the crank. Thankfully the crank looks un-damaged but this pulley is driving me mad lol . Has anyone got any ideas of how to get the pulley off? We have tried using pullers but they slip off. Any advice would be gratefully appreciated as I haven't got much skin left on my knuckles

 

wd40, heat and getting some leverage on the pulley.

 

These can be a nightmare.
lots of WD40, luck and time. You will probably need a new drive cog in the end.
Try to lever from behind the cog against the oil pump, don't go stupid with it and mind the little lugs that stick out as they induce a signal at the crank sensor, so dont snap them off.
If that doesn't work then tap the cog back and forth using the open holes in the front of it, working the WD into the woodruff key groove so as to loosen the contaminate around it.
It has taken me a couple of hours before now to shift one, plus you also have the fact that it probably has some internal damage on its inner side.
Good luck!

Len (Subaru 4You)

 

Thanks Len for the advice. The pullers we were using were very close to getting it off but the jaws were a bit too thick. We were thinking of grinding them down a bit for a better fit. Do you think combining these and some WD40 would be a good idea?

 

Soakin it in WD40 will help a lot. Be carefull of the Crank seal behind the pulley!!!!!

 

Im having a nightmare removing the crank pulley nut! any ideas? done a search and this was the newest most relevent thread I could find

 

Put it in gear and have an assistant stand on the brake pedal.

Put a length of scaffold tube on the end of you 1/2 inch bar, and use this for extra leverage

 

bloody wish i never tightened it up when it came loose now!