Kempe you can use a slide-hammer puller instead of a gear (screw-type) puller. It should come off so easily that it wouldn't matter which you used. From Pauly80's pictures and description your pulley may have developed a groove in the wrong place at some point: it seems it should be a push or light press fit, but it may have been run without the bolt fitted, and has spun on the mating component until it became a bit loose but won't come off because of the groove. Pauly80 suggested this possibility a few posts ago. If that has happened, the hub of the aluminium pulley will have to get reshaped slightly for it to come off at all, but it should only be a shallow groove in a soft, cast aluminium component so a bump or two with a slide hammer, or a light pull with a gear puller, should get it off.
If this diagnosis is correct, you will need to touch up one component or the other with a file before you put it back together, so it doesn't give this problem again. Be careful, though - it sounds as if it has already spun enough to have become slightly loose where it should be a fairly tight fit.
Last edited by grumpy; 03/04/11 03:54 AM. Reason: Added detail
