Spindle pulley removal -- need help -- UGH !!!!

[Brockport Bill 1,662]

i recently got a 42 r.d. mower which has need of rehab - some noisy spindle bearings etc ----- so decided to try to remove spindle pulleys, which i have successfully done on various decks over recent yrs - - and yes, its always a wrestling match but usually winnable !!!! The center double pulley lifted right up off the shaft in my hand  --- I got excited to then move to the side pulleys/spindles only to run into a nightmare!!!!!!!!! I have tried everything I know and i can't get the pulleys off -  daily soaking for over a week with penetrating oil - tried to heat with map gas - tried pipe wrench, vise grips, etc - those pulleys are on those spindle shafts like super glue!!!! I've read different ideas here on RS over the years but I need some new ideas -- help?????? Thanks Bill

[JCM 9,168]

Two flat bars on opposite sides of the pulleys may work if you have not tried that yet ?

[kpinnc 12,065]

I say the good news is that the center pulley came off easily.  Those are hard to find, and typically expensive when you do find one. The outer ones are far easier to replace if you have to.

 

I wish I had some trick to share that saves them, but I don't. If soaking and heat won't break them (depending on you patience level), they may not come off without bending them up, or even cutting them off. 

 

Good luck regardless. You might get lucky and they pop off after a few days of soaking. 

 

 

[Brockport Bill 1,662]

1 hour ago, JCM said:

Two flat bars on opposite sides of the pulleys may work if you have not tried that yet ?

actually, i went to HF and bought two of those pry bars a few weeks ago for this express purpose -- unfortunately, used the 2 bar prying leverage best i could from opposite sides and the bars wouldn't budge the pulley up --- I even tried the bars after i heated the pulleys, plus also after heating,  I soaked again with penetrant hoping the hot pulley would weep in the oil -- i guess cutting pulleys off might be last resort???????? That'll require some fine skill work to not damage the spindle shaft.

[JoeM 7,874]

Something I have done is tap the two holes in the pulley and used a puller. At the same time I also took window/door shims and tapped them snug under the pulley. Once you get some tension on the puller give the center puller screw a few taps with a hammer.

Heat and quench with WD first. 

 

[peter lena 8,631]

@Brockport Bill   this is what you do , rebuilt a number of decks , note in first photo , the pry bar rocker is under the pulley on top of the spindle housing bolts , up against the center shaft mount , strongest spot on pulley , 2 levers , pushing in oposett directions , pops that right off , also note in last picture , look at the added flat idler pulley I  added to the unsupported drive belt  ? also use lucas green grease on / in every related bearing . my decks are quiet , smooth and no bearing whyining . pete

 

[953 nut 55,260]

 

14 hours ago, Brockport Bill said:

daily soaking for over a week with penetrating oil - tried to heat with map gas - tried pipe wrench, vise grips, etc - those pulleys are on those spindle shafts like super glue!!!!

You are on the right track, just need to break the rust bond that is holding them from moving. A few hardwood wedges in three or four places under pulley (tapered opposite one another so they are flat on the pulley) remove the Zerk fitting and a couple smacks with a brass hammer to protect the threads will do the trick.

Edited August 20, 2023 by 953 nut

[daveoman1966 3,752]

If your side pulleys look like this...with a 'lip' on the top edge, rent a 'Power Steering Pump Pulley' puller tool.  Free rent if returned undamaged.  It'll show how to use the tool.  The tool looks like this:  It locks on to that top lip and pulls the pulley off.     

The two pry bars method shown here MAY work...but the right tool will guarantee removal.  

If your pulley does NOT have that 'top lip'....   see my next post.  

 

[daveoman1966 3,752]

To remove a stubborn pulley that doesn't have the 'top lip'. Try this...(having removed the blade):

1) Set the bottom side of the spindle into the hollow of a cement block...leveling the other side of the deck, of course. 

2) Put the TOP NOT on the spindle shaft and thread it to LEVEL with the shaft top threads.

3) Hold the flat side of a ball peen hammer onto that top nut which MUST be level with top of shaft.

4) Using a BFH, whack that ball peen hammer ---like you got a pair.  

5) All you gotta do is break loose the pulley....then it'll lift right off.  

6) when it breaks loose, remove the nut and pulley....

PRESTO !   Pulley off and shaft threads not damaged. 

[Brockport Bill 1,662]

49 minutes ago, daveoman1966 said:

To remove a stubborn pulley that doesn't have the 'top lip'. Try this...(having removed the blade):

1) Set the bottom side of the spindle into the hollow of a cement block...leveling the other side of the deck, of course. 

2) Put the TOP NOT on the spindle shaft and thread it to LEVEL with the shaft top threads.

3) Hold the flat side of a ball peen hammer onto that top nut which MUST be level with top of shaft.

4) Using a BFH, whack that ball peen hammer ---like you got a pair.  

5) All you gotta do is break loose the pulley....then it'll lift right off.  

6) when it breaks loose, remove the nut and pulley....

PRESTO !   Pulley off and shaft threads not damaged. 

wow -- thats an interesting idea -- thanks

[Wayne0 457]

55 minutes ago, daveoman1966 said:

To remove a stubborn pulley that doesn't have the 'top lip'. Try this...(having removed the blade):

1) Set the bottom side of the spindle into the hollow of a cement block...leveling the other side of the deck, of course. 

2) Put the TOP NOT on the spindle shaft and thread it to LEVEL with the shaft top threads.

3) Hold the flat side of a ball peen hammer onto that top nut which MUST be level with top of shaft.

4) Using a BFH, whack that ball peen hammer ---like you got a pair.  

5) All you gotta do is break loose the pulley....then it'll lift right off.  

6) when it breaks loose, remove the nut and pulley....

PRESTO !   Pulley off and shaft threads not damaged. 

PSA

If you're hitting a Ball Peen hammer with another hammer, WHERE SAFETY GLASSES!! I've had hammer faces splinter doing this.

[Bill D 1,922]

Consider using a brass hammer when doing this

[johnnymag3 2,520]

19 hours ago, Bill D said:

brass hammer

Indeed......and a large one...

 

john