I found this volvo 740 1989 at the scrap yard with 210k km and tried to remove front pulley that I want to keep as a spare. Their price is $8.

I removed the 24mm bolt using the rope trick, worked very well.

I was surprised the pulley is still solid in place, the one on my 240 1991 fell alone to the splash pan when I put a new timing belt.

I might want to take the plastic timing belt cover at the same time if I don't break it.

Any suggestion about prying it out or use some penetrant that wont damage the rubber cushion insert as much as is possible ?

Me, I wouldn't want an old pulley as a spare. The rubber hardens over time.

For the amount of work you are putting into getting this old pulley out, you could buy a new one with fresh rubber. A new pulley costs $160 shipped from FCP. Have you put $100+ of your time and energy into removing the old pulley?

Sometime reusing old parts in not the wisest choice.

Spray with PB blaster or Kroil. Whack it with a hammer. Wiggle it out. It will come off.

Hi Roland,

Maybe not funny, but so familiar to be recalling the exact challenge. I was just as surprised it didn't fall off like all those at home did.

I wanted the pulley, and the crank sprocket behind it for a spare, so no urgency or consequence to failure. Biggest beater I have in the junkyard tote is a Harbor Freight* ball pein maybe half a pound if that. Knowing for certain it could only be a film of rust between the crank and the pulley, I tapped around the outer edge with as much swing as I could muster between the pulley and the radiator. It did not take long before it was loose.

Something tells me from reading your posts over the years you would have already tried this, and you're thinking of returning with a puller and worried about the risk of dislodging the old rubber isolator using it. I'd think if you could, you wouldn't want that pulley anyway -- just take the sprocket and the plastic cover.

Did you know there's an outfit doing rebuilds on those vibration dampening (damping?) crank pulleys? I came across it a few years ago in some idle surfing -- no recommendation -- but it seems there's some market for that sort of thing.

Sorry if this isn't much help, but I couldn't help relating the similar experience. It should just fall off.

*Harbor Freight sells China-made tools in the US cheap enough so ordinary folk can afford tools they'd only dreamed of having before this trade existed

--
Art Benstein near Baltimore

"Doc, I can't stop singing 'The Green, Green Grass of Home.'" "That sounds like Tom Jones Syndrome." "Is it common?" Well, "It's Not Unusual."

Still remember trying to get the pulley off my daughter's 760 Turbo wagon to do a timing belt change. Tried everything I had including a puller - heat, lubricant, percussion adjustment, etc. I ended up cutting the bottom of the timing cover to get it off while leaving the pulley in place. It beat the crap out of me.