How to remove pulley from Kohler twin?

[FergusonTO35]

I'm trying to replace the crankshaft seal on my step dad's Kohler twin on his Troy Built riding mower. It's less than 10 years old and hasn't been used that much. I've tried everything I know to get the bottom pulley off. Lots of penetrating oil, two prybars, gear puller, bolt grip puller, tapping from the side with a hammer. I know it's going to have to be replaced, any other suggestions before I cut it off?

 

[EFSM]

Did you heat it? If you're replacing the seal anyway you don't have much to lose.

 

[stretch5881]

I just removed a clutch that was frozen. I welded a nut on the head of a longer crank bolt, so the air hammer bit couldn't slip, sprayed with penetrant, used a prybar and rattled the bolt with the air hammer.

 

[redline4]

Living and working on cars in the rust belt, I use the phrase "it can't stay tight if it's liquid" rather often.
Heat, penetrating oil of some type, heat and force.

 

[Bill G]

Tonight I have to go bore some studs out of gearbox due to a heavy-handed damn moron.

Did I mention I work alone

 

[RCBS]

Dunno if possible but a good whack to the shaft could break it loose. Of course you'll need to protect the shaft while doing so or use a punch. I usually tension a pulley a bit with a scregie before the violence commences. Short of this shock therapy, I have no valid methods to offer that you've not already tried.

 

[FergusonTO35]

I don't have access to a torch that would be suitable for this purpose, fortunately the metal of this pulley is really soft so I should be able to cut it off no problem. I did soak it in penetrating oil again and leave my puller tensioned on it, maybe the continuous pressure will get it to move. This is my stepdad's backup mower so no hurry.

 

[old saw fixer]

What are you using for penetrating oil?
Some are way better than others.
Remember, it took almost ten years to rust on there. Keep the joint wet and give it a few days.

 

[FergusonTO35]

I'm using Kroil and Seafoam brand. I ordered a new pulley last night, it was only $43.00 shipped.

 

[old saw fixer]

Kroil alone would be my choice, I keep a gallon can in the shop.
whichever you use, keep it wet. I've been there, without a big torch you just have to have patience. Tapping the pulley after you soak it will help draw the penetrant into the joint.

 

[stretch5881]

My rust penetrant is 50/50 mix of atf and lacquer thinner.

 

[cus_deluxe]

whack to the shaft

protect the shaft

seems like the kind of thread @Woodpecker would be totally in to.