Small Engines (Lawn Mowers, etc.): Removing a rusted pulley to a drive shaft, propane torch, drive shaft

Question
Mr. Bridgers
I have a Troy Bilt riding mower. Like some others, I am attempting to replace a broken drive belt. I have removed the PTO assembly but the pulley is rusted to the drive shaft. Any suggestions on how I can remove the pulley? Thank you.

Answer
Hello Scott:

Usually I Suggest Soaking the Shaft Area Above the Pulley with PB Rust Catalyst and Allow it Set for a Few Hours and then Repeat this Process a Few More Times Over a Day. The Following Day; Drill 2 5/16" Holes into the Pulley where the Pulley is Attached to the Sleeve. These Hole Go through the Pulley, Not the Center Sleeve of the Pulley. They Need to be 180 Degrees from Each Other and be Far Enough Away from the Center Sleeve to Allow for a Washer to Fit Over a Bolt that will be Used for Pulling the Pulley. Using the Holes that you have Drilled, Use Bolts, Washers and Nuts to Attach a Puller to the Pulley. Apply Pressure to the Pulley. Tap the Pulley All Around the Shaft Area Again and then Hit the Puller Bolt with the Hammer. Repeat this Process if the Pulley is Starting to Move. If the Pulley Did Not Move when you Did the Above Process, then Use a Propane Torch and Heat the Center Sleeve of the Pulley. The Heat will Cause the Center Sleeve of the Pulley to Expand Away from the Crankshaft and Usually the Pulley will Slide Off the Shaft Using the Puller and the Heat Together. Sometimes, you will Encounter a Pulley that is So Rusted that you End Up Bending or Breaking the Pulley. This cannot be Avoided. Before Installing the Pulley Back Onto the Crankshaft; Sand the Crankshaft and then Wipe the Crankshaft Clean with Rubbing Alcohol. Now Apply so Never Seize to the Crankshaft. The Never Seize will Prevent the Pulley from Seizing Up Again and Allow for Easy Removal of the Pulley in the Future. The Holes Drilled Into the Pulley will Not Damage the Pulley. By Drilling them 180 Degrees from Each Other the Balance of the Pulley is Not Effected and it will Perform as Designed. If you Hit a Snag or this Does Not Correct the Problem,  I am Here if You Require More Assistance. Hope this Helps. Let me Know What Happens, Please. May the All Mighty Bless You and Yours. Thanks.

Good Luck

Respectfully

John

PS: I am Allowed to Answer 10 Questions a Day. If you See I am Maxxed Out, then Try Submitting your Question at or Just After 8pm EST (US). My New Day Starts then. Thanks.

Respectfully

John