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Not sounding too promising. When you say you can loosen the bolt all the way, but can't get it out of the pulley, what exactly does that mean? You will need the bolt in some what to remove the pulley and that is what I recommend. I recommend taking the pulley out and inspect everything throughly to ensure that there is no damage in and around the pulley and crank head. If you don't notice anything, I will take a new pulley bolt and thread it up and loosen it and see if there is any play in the bolt. It there is, you may have bigger problems.
I am sure that someone will chime in and offer more help soon.
MPH1972s answer seems like the best approach to me, to make sure everthing is fine. It will entail removing the rack in ouder to get the crank front parts off. However, it you are pretty sure that nothing is goobered up, I would suggest just backing the bolt out as far at it will go, up against the steering rack, and check if you can see any of the threads on the bolt. IF you can, then I would slobber them up with blue loctite and run the bolt back in. Getting the proper torque on the bolt might be rather difficult, but if you can't positivily lock the crankshaft and use a torque wrench, then tighten it as best you can and DO NOT RUN THE ENGINE for 24 hours, long enough to let the loctite set up. If you move or vibrate the loctite after is starts to cure, but before it is fully set, it will loose all its strength and it is a waste of effort. It sound s to me that the original instalation was not loctited, and it was not torques to specification. Good luck trying to patch this togther, but do understand you would be best served to to fix it the difficult way, by removal of all parts, inspection, and re-install with proper torque and loctite.
great...that answers my main question...I wasn't certain that i had to move the rack in order to get the bolt completely out....I guess I do...I was hoping it would be a bit easier than that....oh well....guess I'll wait until the sun goes down and it cools off a bit before i start this process.
I would get a new bolt, and a pin kit, move the steering rack out of the way. Pin the crank and use a new bolt. The bolts are a one time deal unless it happens to be an ARP. Do a search on the forum here on how to install a pulley as is will show how to use a longer bolt the get the pulley started and then use the new bolt. Keeps from stripping the new bolt or the end of the crank.