Hey guys I've tried looking through other posts for help but couldn't find something on removing the pulley. Most has been bolt removal. I can't get the stupid thing unstuck. I have a pulley removal tool but it goes in and then starts threading into the pulley bolt spot until it hits the end and stops. It won't push the pulley off. Now I thought that I could put a cut off bolt into the cam bolt hole and use it as a backing for the puller tool but that ended up crushing the bolt into the space! Which is awful! I now don't know how to get the pulley off or the bolt that's in there! Please help with any ideas.

 

Hi,
bad idea, man, very bad. The cut off piece stuck in your crankshaft, not in your pulley. And you have to get it out, otherwise there is no way to fasten the pulley.

I would try to dismantle the front ( bumper, grille, cooler) to get access in direct line to the crankshaft. Then you have a chance to dremel and drill that entangled piece out, very carefully in order not to damage the thread.
If you manage to get a hole or a slit into the cut off bolt maybe you'll have a chance to twist it counterclockwise. Another way is drilling a hole and cutting an M6 thread into the piece for pulling it out with a bolt.

Good luck,

Fritz

 

ya now i know its a bad horrible idea. I didnt at the time. I thought i was a genius haha. thanks ill try those suggestions and see if i can get it out. it looks like just one side of it is wedged in there though, but besides the bolt how do i get the freakin pulley off. i cant figure that out at all.

 

You need a puller that has a flat bearing that will sit flush on the end of the crank snout. You don't ever want to push against the threads or bottom out the crank hole. The pulley is just pressed onto the crank shaft.

 

+1
You missed that little circular support bearing, which is shown at the bottom right in this tool set:

https://zimber-tools.eu/de/motor-ein...ber-tools.html

 

Dangit! got this far and might have just messed everything up. now i could have damaged the crankshaft. didnt even think that a support bearing like that would be needed. anyone know of a site that has that in the USA?

 

If you have a friend who is handy with a mig welder, you could get a small diameter rod tack-welded onto the stub of that bolt. Then get a slide hammer attached to the rod to try to shock the bolt free.