I started a major undertaking by pulling off my heads to retrieve three broken glow plug tips. All went fine until I got down to the Harmonic Balancer. I need to remove the Harmonic Balancer to remove the Plate in order to realign the Fuel Injector Pump Gear and Re-seal the plate to the block. I soaked the Balancer with penetrating oil, liquid wrench and PB Blaster. I have busted two Harmonic Balance pullers with my Impact. It will not break free. I even tried to heat it up with a torch, trying not to melt all of the seals and rubber in the balancer, I thought this would help but no go. I machined a 1/4" steel plate to bolt into all four holes of the balancer so that the Harmonic Puller would pull evenly on all 4 bolts instead of the 2 bolts that only line up with the puller itself. None of these attempts have even budged the Balancer. I even tried to beat on the balancer with pressure on it from my impact. The impact I have has over 650Ft.lbs of torque and when it runs in on the crank it just stops and cracks the threads on the balancer. And yes I do have the center nut out. Any suggestions that I can try next would be greatly appreciated. Right now my only alternative is to cut the old Balancer off and replace it with a new one.

 

Wow, I've never had one on that tight before. Before you cut it off, you may be able to get the timing figured out throught the hole in the top. Next time leave the gear and housing on the engine. Spin the engine to TDC and look for a Y on the face of the cam gear with a small flexable mirror. If it isn't there, spin it around again to 0. Once you figure out where it is, take a paint pen or similar and mark the tops of the two teeth that are above the Y. Mark the pump gear somewhere you can see it and drop it in there. Use a small flashlight and rock the gear back to see if it's lined up.

It can't hurt to give it a try before you get the torch out again.

 

Problem I have now is I could do what you said and make sure that the gears are timed up. I had them marked before I disassembled them, but If I don't get this balancer off i can't seal the plate to the block, which means coolant leaking into the block and that would be bad.

 

I was wondering if the plate had been disturbed. You already pulled the water pump then? Well, what brand of pullers are you breaking? I'm sure you already know that that air gun is helping them break before their time. Use a good six point socket and flex handle on it. Pull it to where it feels like it's only a flat away from breaking, then put some heat on the center of the balancer. If you've already done this... you have my sympathy.

 

This was my second MAC tools harmonic balancer puller. Thank GOD they have a warranty, the last time the tool man just brought me another one. As far as this Balancer goes, I guess i might have to look at soaking it some more with PB Blaster and then throw some more heat to it and hope it comes off. Where on earth is this thing binding? Could it be a cracked Keyway or something?