I bought a crank pulley puller for the truck so I can get the timing cover off to do a timing job, ended up ripping the threads out of the pullers, screws pulling it off, so I bought a more expensive one, and the crank pulley still won't come off. I already broke one breaker bar, and pulled to the end of the puller threads, am I just gonna have to grab a grinder and grind this pulley off? 4.0 V6

 

I had a hard time with mine too. Ended up destroying the damper in the removal process. Don't be surprised if you end up replacing the pulley. I had to heat the pulley with a MAP torch and used a large 3 jaw puller with a long sacrificial bolt in the pulley bolt hole. The pulley is keyed and the woodruff key tends to rust and freeze it in there. Whatever you do don't whack on the pulley and don't cut it off, you're likely to damage your crank or crankshaft bearing. I was worried I woud do some damage with the heat but I had oil in it still so I took the chance.

 

I just broke a hook off of a puller for a 5.9 cummins on this pulley, since I live in an area where I cant store blow torch products (military barraks) cutting it seems like the best option so far. I still got oil in mine (which probably don't mean anything since I'm tempted to cut it) or I might just use my buddies tahoe to pull it off, but both seem like bad ideas honestly

 

If you are going to cut it, be aware that the crank shaft sticks out about 1.75 inches into the pulley. Don't cut the shaft, I'm fairly certain you will have issues with its balance if metal is removed. The Tahoe is just going to tow it, or you will damage the crank bearings with that kind of load. Get a big 3 jaw and run it down with an impact. If it is set up properly It should be able to get it off. If it's possible, try drilling a tiny hole through the pulley/woodruff key to relieve a bit of tension.

 

You can use this type of bolt on puller from Amazon or Harbor Freight, get two M8 x1.25 pitch x 150mm length to bolt to the pulley. After removing the original balancer bolt, which is a 19mm head, use a sacrificial 1/4 inch x 6 inch socket extension to put into the hole and the puller tool can center itself in the extension. This set up Is what I used and it worked out very well, no issues and it pulled off easily. Always replace the balancer bolt with a new one, these bolts are TTY - torque to yield which means they are to be used one time because of thread stretch. If you reuse the original bolt, you will risk snapping off the bolt or stripping the threads due to bolt stretch. For the 2005 Ford Ranger 4.0 engine the ford part number for the new bolt is E7RY-6A340-B. Torque to 33 ft lbs then turn an additional 90 degrees to complete the process. Be sure to check part numbers and torque specs for your model and year.