Pulley removal on decks

[elcamino/wheelhorse 9,326]

There has been recent discussion on pulleys and spindles recently. My questions is " What is the best, easiest, sure-fire way to remove the deck pulleys from the spindles.  @Pullstart suggested using 2 flat crow bars. My 75-year-old muscles don't work on them flat bars. Someone mentioned driving angled shims. Wood or metal shims? I think I have tried just about every rust solvent I could find. I even tried a pill bottle full of what chemical on top of the shaft of the pulley after a month still no go. Currently I have the spindle and housing (deck was rotten so I cut the housing out) soaking in a bucket of full of liquid wrench or whatever was in the gallon can.

Please give me a clue. Winters project is deck(s) rebuild.  I thought about a HF hydraulic press but can't figure out how that could be used. I know 3 jaw pullers are a no no. 

[Pullstart 62,925]

I don’t remember suggesting that, but cool!  

 

I have used two pickle forks on opposite sides to pull a pulley from a shaft before.  They have opposite tapers to wedge it off.  Tap them in, tap the end of the shaft, tap them again…. It works on engine pulleys, tiller and snowblower ones too, I bet it would work on a deck if you could fit them.

 

Another tip, if the shaft is longer than the wedges allow, you can use a large open end wrench or a stack of ‘em on the shaft too.

[RED-Z06 2,221]

For me.. Ye olde blue wrench has saved me alot of hassle.

[squonk 41,169]

Horror Fright bearing puller. Larger plate fits in to the pulley grooves. Studs bolt to plate and treaded plate thingy. Forcing screw threads into threaded plate thingy. 

 

$55 bucks or a few packs of heaters

 

[elcamino/wheelhorse 9,326]

@squonk I got one of them when are you and Randy coming to use them ? i will have to give it a try on one of those stubborn SOBs  The waldomobile is sitting in the cold shed waiting for you to replace the engine. Been so dry down here I am afraid to use the wood stove, too many leaves and no rain. Tell Randy I have his rake waiting.

[elcamino/wheelhorse 9,326]

@Pullstart What the heck is a pickle fork you mean thing to remove ball joints? All the pickle forks in kitchen are silver or silver plate don't think they would last long being hammered on .

Edited November 19, 2023 by elcamino/wheelhorse
can't spell

[Brockport Bill 1,668]

i asked same question here a few weeks/months ago -- after every idea possible over couple weeks, spraying, various tools etc -- -- Sadly, none worked --- it was as if pulley was welded it was so frozen --  i finally had to cut off the pulley -- then of course came the $60 cost for pulley replacement -- but heck now it has a new pulley -- haha - and my deck rehab came out pretty good - see photos

[elcamino/wheelhorse 9,326]

33 minutes ago, RED-Z06 said:

For me.. Ye olde blue wrench has saved me alot of hassle.

I'll try that next if @squonk bearing remover don't work.

[elcamino/wheelhorse 9,326]

@Brockport Bill I have given serious thought . Just hate to mess up good pulley when I need 3 new complete assemblies to replace double d assemblies. Hoping to save pulleys to recoup  some of the cost for new assemblies with new pulleys to match.

[Gasaholic 224]

Trick of it is getting the force of a puller or pry bar on the HUB of the pulley - I have used variety of tricks over the years - Motorcycle tire irons were my go-to tools because of their curved ends on one end and they're thin to slip under pulley lips in limited space.  Some wheel horse pulleys had grooves in the upper part of the hub where you could use a power steering pump pulley puller - and along the same lines I have drilled and tapped hubs either side of the shaft (where there was enough meat to drill and tap for 5mm or 6mm grade 8 or better screws) and have also drilled holes in the sides of hubs to fit home made puller bolts (grade 8 bolts bent to an L shape with heads cut off, threaded ends through a steering wheel puller with nuts & washers) , but sometimes there's just no saving the pulley , in which case, making sure to have replacement pulleys in hand first, a hacksaw or die grinder outfitted with a muffler cutoff wheel to cut a slot in the hub (or 2 slots in opposite sides for especially stubborn pulleys) and cold chisel to split the pulley and remove.. 

[peter lena 8,649]

@elcamino/wheelhorse   this is what works , the outer edge of a pulley is its weakest area , using  2  wonder bars , rocking on  the spindle to deck  bolts , opposed sides , bar edge up against the spindle hub , strong point , lets you push equally at  either side of the hub. done this a number of times . makes it simple . also a good time to add  a flat idler pulley , to the unsupported  deck belt , bouncing play . just a suggestion , pete 

 

[peter lena 8,649]

@elcamino/wheelhorse  that picture of the broken pulley , those spindle / deck bolts , give you the perfect , leverage / rocker  snug fit for the wonder bar . like KROIL , PENETRATING OIL , first time I did this , the pulley just lifted off easily . the close bolt to pulley shoulder is key , leverage is solid smooth . any time I do a spindle re grease , just makes it simple , Pete  

[daveoman1966 3,752]

This works for me: With spindle still mounted to the deck---blades off---grease zerk OUT. (1) Set spindle housing in the hollow of a 2-web concrete block. (2) balance other end of deck with a block, making the deck level (3) Put the spindle nut back onto the shaft and thread it down to about 1/4" above the pulley (4) Hold the FLAT of a small ball peen hammer (brass) on top of the shaft (5) WHACK the ball peen hammer with a BFH...like you got a 'pair'...don't be BASHFUL---. (6) Shaft will drop 1/4"...breaking loose the pulley.  (7) remove the tp nut..   PRESTO---Pulley off.  

If you've cut the deck shell to remove the spindle, hopefully there is enough of the sheet metal left to do this.  If not, then find a STEEL pipe just big enough to set outer edge of the sheet metal...4 or 5" maybe...as a substitute for the concrete block. 

Edited November 19, 2023 by daveoman1966

[Brockport Bill 1,668]

6 hours ago, peter lena said:

@elcamino/wheelhorse  that picture of the broken pulley , those spindle / deck bolts , give you the perfect , leverage / rocker  snug fit for the wonder bar . like KROIL , PENETRATING OIL , first time I did this , the pulley just lifted off easily . the close bolt to pulley shoulder is key , leverage is solid smooth . any time I do a spindle re grease , just makes it simple , Pete  

tried the pry bars, including heat, penetrating oil, etc multiple times over a week  - unfortunately pry bars wouldn't lift off the pulley 

[Brockport Bill 1,668]

3 hours ago, daveoman1966 said:

This works for me: With spindle still mounted to the deck---blades off---grease zerk OUT. (1) Set spindle housing in the hollow of a 2-web concrete block. (2) balance other end of deck with a block, making the deck level (3) Put the spindle nut back onto the shaft and thread it down to about 1/4" above the pulley (4) Hold the FLAT of a small ball peen hammer (brass) on top of the shaft (5) WHACK the ball peen hammer with a BFH...like you got a 'pair'...don't be BASHFUL---. (6) Shaft will drop 1/4"...breaking loose the pulley.  (7) remove the tp nut..   PRESTO---Pulley off.  

If you've cut the deck shell to remove the spindle, hopefully there is enough of the sheet metal left to do this.  If not, then find a STEEL pipe just big enough to set outer edge of the sheet metal...4 or 5" maybe...as a substitute for the concrete block. 

i used the hammer "whack" technique as you described  - however, regretably it didnt work

[peter lena 8,649]

@Brockport Bill  like everything else , there are variations on each and every model , for the 3 decks I have , this is the deal , I also , start a Kroil soak , with any removal of , blocking soak  access , do that days out , or more .  that goes for any service area . pete 

[elcamino/wheelhorse 9,326]

@Brockport Bill  I know the feeling , two pulleys came off easy ,the third acts someone welded it on.

[953 nut 55,377]

I had good results using four wooden wedges cut to size and placed over the four bolts that attach the deck and spindle. Once they are tapped into place a couple of strong blows with a five pound brass hammer popped the pulley off. If you don't have a brass hammer a scrap piece of walnut or cherry wood and a BFH tool should do the trick without damaging the threads.