This should be an easy one......

I am putting the pulley back on my '94 PS pump shaft.

I am using the Autocraft AC 525 five part kit for removal and installing GM pulleys. It worked great for removing the pulley. However, I can not get it to work for installing.

The install part of tool looks just like the FSM tool (J25033-B).

The tool has two different diameter threaded sections beginning with a 3/8 thread and then tapers to a 1/4 thread (approximate measurements....these threads may be metric, I have not verified).

The smaller diameter shaft is about 1-3/16" long and it inserts into the PS pump shaft first. However, it bottoms out before the larger shaft threads can take hold into the PS pump shaft. I assumed that there was going to be another threaded section inside the PS pump shaft for the 1/4 inch tread to engage, ....but apparently not?

The nut / sleeve (bad word, but cannot think of better description) assembly that pushes the pulley onto the shaft are located on the larger diameter.

Does this make sense so far?

Okay. So....if the hollowed out section of the PS pump shaft is not long enough to allow the 3/8 to engage and/or there is no smaller female thread inside the shaft for the 1/4 thread to engage, then something is wrong?

Plan B. The kit came with another bolt. It will screw directly into PS shaft. So I remove the nut/sleeve assembly from initial set up and place on the long bolt. I am now able to screw this into the PS pump shaft until it bottom out and then I begin to turn the nut/sleeve to place the pulley onto the PS shaft.

Problem: As I turn the nut/sleeve, the pulley does not go on....instead the bolt backs out. Even if I hold the end of the bolt with a socket. I also notice that the PS pump shaft is turning.....makes sense I guess...

I do have a Plan C. Remove the PS pump assembly and take down to local Chevy dealership and have them install pulley.

I really think that I am missing something obvious here.....

Also, in my frustration I did begin to hammer the pulley onto shaft (we have all been there). I had enough sense to walk away quickly thinking that this is not a good idea.....I did not hit it hard so hopefully did not damage any seals.

Feedback welcome but be nice....I have had a long go of it on this project !

 

I have never done this job, but I'm looking at the drawings in the FSM- Is it possible to thread a nut on the tool shaft such that when the tool is in the shaft, you can lock it into the shaft and then use the installer to press the pulley on? The nut would have to fit inside the pulley bore. Don't laugh at me- I know it's a wild-a**ed guess.

 

There is not enough tolerance for the nut to fit inside the pulley bore.

I must not using the tool correctly.

I cannot see inside the PS shaft but I wonder if there is a place for the smaller shaft to screw into but it is filled with crud and will not allow the smaller threaded piece to thread.

 

I think this is how the tool works. The small thread to the right threads into the pump shaft.

 

Got it! The trick for me was to hold the pulley while turning the bolt. Otherwise, everything turns and it goes nowhere.