05 MCS Crank Pulley replacement- won't come off
 

I recently found out that the crank pulley on my wifes car has gone bad. I attempted to do the R & R myself, but after I put ALOT of pressure on the pulley trying to remove it, it wouldn't budge. The car is now at the stealer and THEY cant get it off to replace it....Anyone ever come across this?
I would be hesitant to have them use any kind of heat since the pulley has rubber internally and the crank seal could be in jeopardy as well. Any ideas would be appreciated.
Tim

If you haven't broken your puller or the M6 threads in the pulley then you haven't pulled hard enough. I would cut it off before using heat.

Jeremy

I 2nd cutting before heat, Grinders are fun!!!!:nod:

I had to have large flare nuts welded to the pulley, it's a strange alloy and it was very difficult to weld, I drilled holes beneath the nuts so the grip bolts could extend from the other side for good thread purchase. I used a strong bolt grip puller, against a hardened thread protector (allen head bolt), when the extractor bolt was under max tension, struck the bolt head, tighten, strike, and repeated till it could be moved with striking.

If you decide to use a welder on it, be sure to mask the rubber parts like the axle boots, and the entire area with heat resistant material, I used multiple layers of heavy duty aluminum foil.

Tap the bolts out to a larger size and use a standard balancer puller. If it's at the dealer they have the tool that screws in the crank bolt hole to press against. If they still can't get it off, find an aftermarket shop with a resourceful old school mechanic. This is not that hard of a job.

Crank pulley
 

That was the hardest part of the job, to get crank pulley nut off. Had to get a 6 ft long pipe to break nut loose, after that smooth sailing....