Has anyone ever successfully removed a gm power steering pulley from the shaft without totally destroying it?

 

Yup.

Is your real question HOW to remove it? Start by telling us if you have a press-on pulley or one held with a nut. The press-on pulleys need a special tool, available at any auto parts store.

 

Yep it used to be press on. I figured there had to be a tool made,for it. I don't need it now i need a pulley. Thanks for the response Joe. I hope it keeps the next guy from screwing theirs up!

 

Don't use a 3 jaw puller, you'll bend the pulley.
Rent or buy a p/s puller, some kits have the installer too. A new p/s pump might even have a bolt to install the pulley. Its just a long 3/8 bolt with a nut & washer.

 

If it had a nut on the shaft, but no lip, you can't use that tool above.

What kind do you have?

With the tool above, an impact tool is advised, and gloved hands.

http://www.getahelmet.com/jeeps/maint/steeringpulley/

 

Mine was press on and no nut. The shaft had an Allen wrench slot. I tried the three jaw puller and bent the heck out of the pulley. Lesson learned

 

I've used a small tie rod end puller with success (at least I think that's what it was - was a couple of years ago).
It had straight jaws, and they fit nicely into the puller groove, and I just gave it a whirl and "POP!"

- Eric