Tech. Advice/Thoughts needed Plz! I did a booboo

[t_ahan]

i am hoping some1 has had this same issue and can give me an idea on what i need to do!

2003 Denali
hydroboost power steering pump pulley removal....
my pulley remover(matco) ate the lip off the power steering pump pulley when i was pulling the motor out awhile back. The tool was about to completely chew the lip so i stopped once i had enough room for the power steering pump bolts to come out and left the pump with the pulley 60% off the shaft and the tool still on, just laying off to the side.

install time came and i put its all back together like an idiot...now(2yrs later) my pump is leaking and its time to replace it but im not sure how this all going to work out so i am trying to prepare for the worst....(tell me if im wrong or missing something)new ps pump/pulley/acc.braket...

i know i could have avoided this by heating the pulley during removal the 1st time and or while the motor was out i should have replaced it then (YES I FEEL DUMB!!)

CORRECTIVE ACTIONS i am thinking
1.weld the pulley remover tool on to the pulley?
2.pull the accessory bracket w/pump and go to town on this B and try everything to separate an reuse the bracket
3.attempt to cut the shaft????

i dont know i could sit here and type a million things so i wanted to hear from every1 and see if any1 has done this b4

keep in mind i just moved to an apartment(location1) and now have my tool box at my dads(location2) and my air compressor at a friends (location3)

location 2 has a garage and private drive way so i think i may do it there + if i cant get it done in the late night i can crash at the old mans place and jump back on it in the am!

thanks every1

 

[bottomline2000]

4. have you tried a different pulley puller? I rented the tool from Oreilly's and it pulled it off no problem. it wrapped around tight and didn't even scratch it..

 

[SLCHOE]

This to remove: http://www.amazon.com/gp/product/B0..._m=ATVPDKIKX0DER&pf_rd_r=1JRNATCA8NH61M8VS4SA (Don't use the installer from this kit)

This to install: http://www.amazon.com/OTC-7005-Steering-Pulley-Replacer/dp/B0002SRF8K (Far better installer as it incorporates a ball bearing into the design.

Never had a problem with either of them.

What Matco puller were you using? Pic of the pulley?

If the above puller wont work for some reason just pull the pump/pulley/accessory bracket off as a unit and cut the pulley off the shaft. You are replacing the pump anyway and as it sounds the pulley probably isn't any good anymore either. New pump/pulley. Done.

 

[bottomline2000]

This to remove: http://www.amazon.com/gp/product/B0..._m=ATVPDKIKX0DER&pf_rd_r=1JRNATCA8NH61M8VS4SA (Don't use the installer from this kit)

This to install: http://www.amazon.com/OTC-7005-Steering-Pulley-Replacer/dp/B0002SRF8K (Far better installer as it incorporates a ball bearing into the design.

Never had a problem with either of them.

What Matco puller were you using? Pic of the pulley?

If the above puller wont work for some reason just pull the pump/pulley/accessory bracket off as a unit and cut the pulley off the shaft. You are replacing the pump anyway and as it sounds the pulley probably isn't any good anymore either. New pump/pulley. Done.

that's the puller I used. I believe this one has a bearing in the install part as well. I haven't put the pulley back on yet, but should know if it works this week.

 

[SLCHOE]

that's the puller I used. I believe this one has a bearing in the install part as well. I haven't put the pulley back on yet, but should know if it works this week.

The puller has a full 360 circle side that fits over the pulley and if reversed is a double "half-moon" side. The full circle side goes around the pulley. I think you might have used the tool improperly and damaged the pulley.

 

[bottomline2000]

The puller has a full 360 circle side that fits over the pulley and if reversed is a double "half-moon" side. The full circle side goes around the pulley. I think you might have used the tool improperly and damaged the pulley.

I'm not the OP of this thread. I didn't have any problems getting my pulley off. It didn't even scratch it when I took it off.

 

[SLCHOE]

I'm not the OP of this thread. I didn't have any problems getting my pulley off. It didn't even scratch it when I took it off.

Yeah that waas directed at the OP. Sorry.

 

[t_ahan]

it may have been operator error(me).....but i have never had a problem with the tool on other vehicles other than my own this one time.... the lip is gone, no out of the box tool will take this thing off! lol ill either weld something to the pulley or like already mentioned "pull the bracket and cut the pulley off!

thanks for everyone's input...i was shocked when it happened, i have replace **** who knows how may press fitted pulley power steering pumps and never had issues unless it was a plastic pulley

i will try to get some pics of the tool and pulley

again thank you all

 

[t_ahan]

this the tool i used:
http://www.matcotools.com/catalog/product/PR5239A/POWER-STEERING-PULLEY-REMOVER-KIT/