Could you assemble a combination of the HF tool and two small collars or "keys" that slide into the grooves? That way you will be applying the puller to a "positive" rather than hoping the tool wiil fit into a recess. You'd need to find a piece of bar stock that fits very snugly into the recess on the pulley (maybe 3 mm thick or so?), cut it down so it sticks out maybe 3/16 inch and then apply the puller.

Good idea
 

Yes good idea Yak - I tried something similar with some bits of 90 degree steel angle that was thin enough to fit in the slots on the pulley. However, on the pulley I tried this on, it turned out that the pulley was more or less glued in place with paint. I think the solution you suggest would work in most cases though.

As my attempt didn't work I didn't bother posting it.

I'm not sure if I've said this before (probably) but if anyone who is stuck and is reading this - if the puller suggestions are not working for you (TRY THESE FIRST THOUGH) knock the pulley off of the shaft with a brass drift. When the pulley is really stuck on there you will make less damage with a brass punch than you will by trying to use a puller on the V groves where the belts go... This works best for power steering pumps with the flatter pulley - I haven't done this on the bell shaped ones (yet)

Better late than never!
 

Well I said I'd do that 3 months ago - and guess what? I've just found the photograph.

If anyone has trouble getting one of these pumps to work after they've taken it apart try cleaning this bit (note the white stained fingers due to excessive and aggressive use of brake cleaner!)

I have rebuilt a few of these pumps. The first one I did is the one on my car about a year ago. It's not that difficult at all. I tried several pullers and none fit that well. I found that you can get the pulley off the shaft rather easily if you hold the pump up by the pulley, loosely install the nut, and smack the nut a few times with a hammer. Popped right off for me and no damage to the pulley. Remember to keep track of the woodruf key.

No need to spill the vanes out, either. With the pulley off, use a ground down punch or similar tool to puncture the shaft seal and pry it out. Reinstall new seal with the help of a deep well socket that fists the seal diameter.

Now you can use a C-clamp to open the back of the pump. Install the shaft bolt and attach the C-clamp to compress the back plate so you can remove the snap ring. Be careful not to push the shaft into the pump when you remove the clamp or you will spill out the vanes. Replace the rear O-ring. Lube and reassemble. Don't forget the washers, etc that may have come out.

Replace filter and prime the pump with ATF before reinstall.

Thanks for the pulley tip - I might try that this weekend (just for fun)

I tried the same method for removing the pulley and both the pulley and shaft came out!

When I tried putting the shaft back in nothing keeps it locked in place. I tried looking for a snap ring but to no avail.

Help...what do I do now?

Thanks..!
Paul

I don't know how that is possible. Can you post a picture of what happened?

I threaded the nut half way and then I held on to the pulley while hitting the nut with a hammer which caused the pulley and shaft to come out in unison.

You can see a groove on the shaft but I do not see a snap ring or similar unless it fell into the vanes portion...in any case I need some help on how to proceed...

If you look in chapter 46-720 in the FSM you'll see that there is a ring that goes on the shaft.

Can someone post that page and any instructions on how to install the shaft with the ring...

PM sent

Thank you Tristan...
I finally found the clip stuck to the back the vane housing...I reassembled and all is working fine...
Paul

I'm glad you got it figured out. I have never seen one come apart like that.

P.S.Pump Sealing
 

T.T.T.

I ran across this whilst planning to re seal two weepy (at rest only, never when driving / observing with the engine running) pumps .

Lots of good tips here, I hope to only need to replace the front shaft seal .