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Wed Mar 26, 2003 6:26 am

Posted this on Google newsgroup also.

I decided to replace my stock pulley with a degree pulley. I didn't
want to pull the engine just for this, so I chose to remove the old
pulley WITHOUT a puller tool. What a BEE-ACH (read BITCH). Finnaly
got it off using the double screwdriver leverage method. Now...the
new pulley just doesn't want to "slide" on. Not much room behind the
engine to use a hammer or a block of wood. Any tricks? Thanks for
any help.
Don

Wed Mar 26, 2003 7:07 am

Make sure that you have the slot on the pulley and the woodruff key lined up, then you just have to gentlly wiggle it on, I used some wd-40, but I imagine if it's bad you could even use some wheel bearing grease, then torque it down to the correct setting. Good luck and be patient

Wed Mar 26, 2003 7:57 am

yes. this saved my life... gently heat the new pulley in the oven (slow radient heat) to about 400 degrees for 15mins. this will let the metal expand just enough... slides on like butter. use oven mitts. no grease. no wiggle. just right.

Wed Mar 26, 2003 8:25 am

How did u get yours off? Please email me at maj1@aiosolutions.com I have a degree pulley I want to get off but there seems to not be alot of room to play with any ideas?

Wed Mar 26, 2003 8:39 am

(asking me?)... i used a modified steering wheel pulley. i'll send a JPG to you. you could use most any puller tool, though.

Wed Mar 26, 2003 8:43 am

I used two pry bars, one on each side and just jerked for a while and it came off... wimmer that's a great Idea I'll remember that.

Wed Mar 26, 2003 8:43 am

First thing is Don't drive the new alum. Pulley on. It Should slide on easy, and slide off easy later. If the end of the crank a has some rough spots on it, then emery out the new pulley until it slides on. Some mechanics install the key with a hammer and it becomes deformed. Its better to open up the new alum pulley then force it on. Do not heat up the new pulley to get it on. This will help installing it but when it's time to remove it the pulley will most likely be destroyed. "Parts Book" Schematics and VW part numbers. -> http://www.1800vw.com

Wed Mar 26, 2003 8:57 am

i have heated and reheated my empi pulley to get it on (3 or 4 times) and its as strong and straight as ever. when i remove it, i methodically and slowly use a puller tool (with the wiggle method, if you get too carried away, you can damamge stuff by the torquing force -- i tried this before the pulley and found it to be unsettlling)... i suppose, you'll have to judge exactly how bad your fit is... i've also slightly openned up the pulley hole with some 600grit wet/dry. the heat method has worked the best though... but dont take a torch to your motor to get to get it off... use a pulley (and when you heat for installation, use slow, even heat (oven)).

Wed Mar 26, 2003 9:23 am

Thanks to all for your advice. I do believe there are some rough spots due to the fact that I literally pried it off. I tried to use a harmonic balancer puller and a steering wheel puller, but there was just not enough room. I think I will use some emory cloth to smooth out the shaft and then apply heat as a last resort. Thanks again.
Don

Wed Mar 26, 2003 3:40 pm

careful with abrasives on the crank shaft. if you f* that up, you're cracking open your engine. a pully'll only. cost you $30 ...