Anyone else go through the turmoil I'm experiencing with pulley removal?

Firstly, I highly suggest not using a 3-claw puller. Once bent, it is downhill from there.

I ended up engineering a removal tool, but the pulley was so bent that I could not get good surface contact for even force. Thus it didn't pull.

I've now had to result to cutting the pulley, down to the shaft (which drives me crazy)

And I'm still having trouble getting to the back 1/4" of material cut.
I've resulted to using a very fine carbide burr and I'm still having trouble.

End result, it is looking like I will need to buy an entire new snout and replace existing.

I've only seen one company with a decent tool that they do not sell and you need see it in use in their vids which leads me to believe their tool is quite complicated as well.

If anyone else has had this experience, chime in. Post pics if you came up with a solution.

 

Like this???

 

Which tool did you use for removal?

I attempted to use 3 claw puller and it resulted in bending the back of pulley.
Then I attempted to cut reliefs. Should have cut reliefs first but the 3-claw was suppose to work.


Pulley has been removed now. Have a score mark from cut off wheel, but it's off at least. As it is an interference fit, it still should hold fine... just a very stressful experience.

Just need to sand snout now and install new pulley.

 

 

This would work on the 4.2 pulley, but not the 5.0 pulley, as the shaft is hidden by the pulley itself.

 

That was Mandrake who did that cross-hack in the front, he just used a normal 3-jaw.

 

lol... you have to remove the plastic cap that covers the end of the snout shaft first.

I used an Autozone three jaw puller and it came off no problem once I made those cuts.