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The special tool holds onto the hub on the pulley and pushes on the shaft. It's not that special, you might be able to fab up something to do the same thing.
If that's not an option, you might be able to get some steel bars between the pulley and the pump to support the pulley, then press the shaft out. I'm not sure if there's room for that, or if it will support the pulley hub to prevent damaging the pulley in the process.
No matter what way you go, throwing a lot of heat at the pulley hub will help make it expand so it won't take as much force to get it off. But the only time I ever tried this it took a lot more force to get the pulley off than I expected and I ended up bending the pulley before I was done. I bought a new one. Hope it goes better for you.
Shouldn't have been any problems making one if i had access to a welder, but i don't.
Ah well, guess the truck will be sitting 'till next week so i can get the bits i need.
Why the hell they couln't just put the pulley on splines and hold it in place with a nut/bolt, or even just a circlip? Bloody engineers...
No, it's to save dimes in assembly. The car companies go through an awful lot of dimes that way, so it makes a big difference to their bottom line. They know we're going to buy the tools from NAPA or something anyway, so they don't benefit from that. Sucks for us shade-tree mechanics of course, but it is big money to them.
By the way, I'm a Production Support Engineer for a manufacturing company that designs, assembles and sells products into a bunch of different markets. We don't sell directly to any car companies, but we do sell into a number of their suppliers. And if you think car companies are money-grubbers toward their customers, just imagine how their suppliers feel!
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