PS Pulley REMOVAL 101 - w/o damage
July 9th, 2015 | 04:10 AM
#1
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Joined: Dec 2011
Posts: 7,286
PS Pulley REMOVAL 101 - w/o damage
Needed to remove the pulley w/o damaging it the other day. I managed to get photos. This is for pre-puller-lip pumps, the kind where a nut retains to keyed shaft then it's just friction.
If you pry the pulley or touch it with a puller or any such tool, it is ruined.
Here is the process used.
1) get a helper and some gloves.
2) using an impact, remove the nut- typically 7/8 tool size. Hold pulley with gloved hands. Spray lube before and after nut removal.
3) put nut back on, just until flush with end of shaft, to prevent shaft damage while forcing the shaft.
4) Helper holds pump with pulley horizontal using gloved hands, above a soft cushion to protect the pump. Apply brass hammer or perhaps a scrificial piece of aluminum between striker and shaft/ nut. Air hammer shown directly on the shaft/nut, not the best way, but it worked. If shaft moves so that nut is against pulley, you are almost there. If not, you may need to apply heat to break the friction bond.
5) Remove nut again, and continue to hand hammer [brass hammer] or air hammer [preferably with brass drift on the shaft] until the pump drops out of the pulley.
Pump should fall free to the padded surface below, leaving helper holding the undamaged pulley.
NOW you can get those brackets off and clean, change, polish, etc. on all the individual pieces.
USE GREASE or anti-sieze on the pump shaft/ key when reassembling. The nut is self locking prevailing torque type. Use a new one if possible, but they can be reinstalled if need be and still serve the purpose.
If you pry the pulley or touch it with a puller or any such tool, it is ruined.
Here is the process used.
1) get a helper and some gloves.
2) using an impact, remove the nut- typically 7/8 tool size. Hold pulley with gloved hands. Spray lube before and after nut removal.
3) put nut back on, just until flush with end of shaft, to prevent shaft damage while forcing the shaft.
4) Helper holds pump with pulley horizontal using gloved hands, above a soft cushion to protect the pump. Apply brass hammer or perhaps a scrificial piece of aluminum between striker and shaft/ nut. Air hammer shown directly on the shaft/nut, not the best way, but it worked. If shaft moves so that nut is against pulley, you are almost there. If not, you may need to apply heat to break the friction bond.
5) Remove nut again, and continue to hand hammer [brass hammer] or air hammer [preferably with brass drift on the shaft] until the pump drops out of the pulley.
Pump should fall free to the padded surface below, leaving helper holding the undamaged pulley.
NOW you can get those brackets off and clean, change, polish, etc. on all the individual pieces.
USE GREASE or anti-sieze on the pump shaft/ key when reassembling. The nut is self locking prevailing torque type. Use a new one if possible, but they can be reinstalled if need be and still serve the purpose.
July 9th, 2015 | 07:40 AM
#4
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Joined: Jul 2013
Posts: 1,815
From: Mo-Ray-Al, K-Bec.
I'll just throw in ... I never rely on a puller to force a pulley off. Just to apply tension. Same thing with the ball joint separator I use. http://www.princessauto.com/en/detai...or/A-p8004135e
I apply it and add just a bit of pressure. Then take a hammer and tap around it. Check the bolt on the puller ... where did the pressure go? Add a bit more tension ... tap again. Repeat until you're holding multiple parts. It was quite shocking discovering just how much effect those taps (with a 16oz ball peen) had. I discovered it with separating a taper ball joint from the knuckle .. but now I do it for pretty much everything.
I apply it and add just a bit of pressure. Then take a hammer and tap around it. Check the bolt on the puller ... where did the pressure go? Add a bit more tension ... tap again. Repeat until you're holding multiple parts. It was quite shocking discovering just how much effect those taps (with a 16oz ball peen) had. I discovered it with separating a taper ball joint from the knuckle .. but now I do it for pretty much everything.
July 9th, 2015 | 09:56 AM
#5
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Joined: Dec 2011
Posts: 7,286
I will repeat in case someone reads the above
If you TOUCH the pulley with ANY TOOL it will bend and be ruined.
Use the above Rocket Science Approved method only.
touch the pulley only with your hands
use gloves to protect the hands if need be.
when you apply heat, sometimes lots of it, the need becomes greater.
Unless the pulley is already written off, then go ahead and mangle it.
If you TOUCH the pulley with ANY TOOL it will bend and be ruined.
Use the above Rocket Science Approved method only.
touch the pulley only with your hands
use gloves to protect the hands if need be.
when you apply heat, sometimes lots of it, the need becomes greater.
Unless the pulley is already written off, then go ahead and mangle it.
Last edited by Octania; July 9th, 2015 at 07:14 PM.
July 9th, 2015 | 09:41 PM
#6
Registered User
Joined: Jan 2009
Posts: 4,087
From: Too close to Toronto!!
That's just great! Now I have to go out and tear my PS pump apart and clean and paint it. Just another chore I was putting off until someone pointed me in the right direction...Thanks for this. By the way, I usually wear steel toed boots when working on the vehicles. Statue.
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