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I am sure that there are 1 or 2 tricks out there for removing a fan that seems mated to the alternator shaft/keyway that I have not tried. I've always been able to use elbow grease plus "soak overnight in penetrant" but this time I seem to have met my match. I'm obviously looking for quick options short of removing the shroud, etc. Is there a tool solution, process, folklore, legend, myth........
This IS a pain...
Seems to me the fan is an aluminum / mag alloy and the shaft is steel, so galvanic corrosion will be the culprit. I always had luck too with soaking overnight and lots of elbow grease. Will careful use of a puller work? Maybe put a couple pieces of wood behind the fan to spread the load using the puller... Try putting some pressure on it this way then tapping (vibrate) the shaft with either a brass hammer or a hammer and a piece of wood. Good Luck
it looks like you could put 4 thin nuts between the pulley halves, and thread some bolts through the pulley holes to the face of the alt. (disclaimer......i'm not sure if the front of the alt. could take it if she's siezed tight.) if you have a puller , using the blocks of wood to distribute the load sounds mucho better.
pb blaster works alot better than wd-40.
try a dab of anti-sieze on the reinstall.
My experience is that "Aero Kroil" by Kano Laboratories in Nashville, TN (615-833-4101) works even better than PB Blaster.....forget WD40.