Removing Mower deck pulleys

[Brockport Bill 2,497]

here's a new angle on removing mower deck pulleys from spindles that have been "rust welded frozen" on the spindle shaft.

i have participated in numerous threads on this topic and am back in situation again  -- using penetrant, map gas etc -- the two crow bars - hub puller etc. no luck !!!!!!

 

It was suggested to me I need to get pulley collar hotter - and was suggested to use " Heat Induction Bolt Remover" -- or also maybe called "Induction heater" --- Has anyone used this tool to heat and remove the deck pulleys?

I watched one video and the guy said when removing a nut the heat process will destroy the nut.

 

Does that suggest the collar on top of pulley on the spindle shaft would be deformed ? I don't want to have to get new pulleys but if that's necessary then I guess that's the cost of removing the pulley ?

 

any insights from anyone using this Heat Induction tool method? thanks

 

 

 

[8ntruck 9,365]

I've never used one, but I have seen induction heaters used in production processes.  The induction heaters are capable of heating things to a bright orange - hot enough to mess up any heat treatment the heated piece has.

 

Chances are a heat induction bolt remover won't get quite that hot.  It probably has an adjustment for the heat level.

Edited October 30 by 8ntruck

[sqrlgtr 4,154]

 

I have this one and it does indeed work well. I have not used on mower deck pulleys but see no reason why it wouldn't work. It has helped with a few "frozen bolts" though. I like it a lot better than haveing to use an open flame for heat.

Edited October 30 by sqrlgtr

[953 nut 70,043]

Cut four wooden wedges from hardwood, place two of them under one side of the pulley where the tip of one is over the tip of the other, do the same on the other side of the pulley. tap on each wedge going from side to side so the upward pressure will be even. Continue driving the wedges in until they are as far as they will go. put the nut on your spindle shaft to protect the threads and give it s good hard hit with a BFH tool. The pressure from below and the shock to the shaft should do the job.

 

[peter lena 10,103]

@Brockport Bill    ever use a WONDER BAR ?  2 of them  one one either side , of the pulley hub , 90 deg  swing on bottom , push them both  OUTWARD  / AWAY  FROM MOUNT  POINT , solid swing leverage  , makes for  easy  removal ,also a perfect time to  do a related , bearing clean out  ? lubrication failure , LUCAS  X TRA HD GREEN CHASSIS GREASE , 550 deg flash point , polyurea rated , stays with bearing . all my decks , and mule drives , as well as  pto cone , needle bearing , have this , never  burned out a clutch disc, that pto  lever start , is a gold mine for improvements , pete  .q=wonder+bar&rlz=1C1CHBF_enUS866US866&oq=wonder+bar+&gs_lcrp=EgZjaHJvbWUqBwgAEAAYjwI    

[Brockport Bill 2,497]

16 hours ago, peter lena said:

@Brockport Bill    ever use a WONDER BAR ?  2 of them  one one either side , of the pulley hub , 90 deg  swing on bottom , push them both  OUTWARD  / AWAY  FROM MOUNT  POINT , solid swing leverage  , makes for  easy  removal ,also a perfect time to  do a related , bearing clean out  ? lubrication failure , LUCAS  X TRA HD GREEN CHASSIS GREASE , 550 deg flash point , polyurea rated , stays with bearing . all my decks , and mule drives , as well as  pto cone , needle bearing , have this , never  burned out a clutch disc, that pto  lever start , is a gold mine for improvements , pete  .q=wonder+bar&rlz=1C1CHBF_enUS866US866&oq=wonder+bar+&gs_lcrp=EgZjaHJvbWUqBwgAEAAYjwI    

upon your suggestion couple yrs ago i got two bars and try using them after penetrant and heat but bars still wont break the bond -- 

[Brockport Bill 2,497]

19 hours ago, sqrlgtr said:

 

I have this one and it does indeed work well. I have not used on mower deck pulleys but see no reason why it wouldn't work. It has helped with a few "frozen bolts" though. I like it a lot better than haveing to use an open flame for heat.

i just watched a  couple videos of this tool -- plan to order if i am not successful one more day of penetrant and map gas heat -- and using wedge technigue to pry them off from underneath - - if not i plan to buy the heater tool -- just hoping it doesn't deform the collar on the top of pulley and make the pulley unusable????? thanks for info

[cafoose 3,883]

On 10/30/2026 at 5:57 AM, sqrlgtr said:

 

I have this one and it does indeed work well.

I may need to borrow that some day 

[Lee1977 7,807]

Those pressed steel pulleys don't last forever anyway. I had a set worn so bad that when I got into heavy grass it just quit cutting.

[Brockport Bill 2,497]

On 10/30/2026 at 5:57 AM, sqrlgtr said:

 

I have this one and it does indeed work well. I have not used on mower deck pulleys but see no reason why it wouldn't work. It has helped with a few "frozen bolts" though. I like it a lot better than haveing to use an open flame for heat.

bought theHeat Induction tool with the hope it would heat the deck pulley collar sufficiently to pry it off -- sadly it did not work -- tried on both outside deck pulleys heating them and then 2 pry bars to get them off the spindle shafts -- no luck -- very disappointed  -- apprently the corrosion has "rust welded" them onto spindle shaft - no alternative but to cut them off - sucks!!

[sqrlgtr 4,154]

11 hours ago, Brockport Bill said:

bought theHeat Induction tool with the hope it would heat the deck pulley collar sufficiently to pry it off -- sadly it did not work -- tried on both outside deck pulleys heating them and then 2 pry bars to get them off the spindle shafts -- no luck -- very disappointed  -- apprently the corrosion has "rust welded" them onto spindle shaft - no alternative but to cut them off - sucks!!

Hate that it didn't work for you. The heat/expansion is supposed to break the rust weld maybe try again using a puller. I never had any luck with sumin really stuck trying to use any type of pry bars always had to use some sort of puller when the going got tough.

[Brockport Bill 2,497]

9 hours ago, sqrlgtr said:

Hate that it didn't work for you. The heat/expansion is supposed to break the rust weld maybe try again using a puller. I never had any luck with sumin really stuck trying to use any type of pry bars always had to use some sort of puller when the going got tough.

yup = sucks -- both my son and grandson tried with 2 ft pry bar ( 9 strong guys) after heating -- i had tried puller last week after using map gas -- my son suggested try puller with impact socket - -so one more attempt tomorrow last resort of cutting them off -- UGH !

[sqrlgtr 4,154]

18 minutes ago, Brockport Bill said:

yup = sucks -- both my son and grandson tried with 2 ft pry bar ( 9 strong guys) after heating -- i had tried puller last week after using map gas -- my son suggested try puller with impact socket - -so one more attempt tomorrow last resort of cutting them off -- UGH !

did the induction heat gun get the pulley hub red hot? I have not used mine on any pulleys, but it did get the bolts/nuts I used it on red hot. Also used it to heat up a shifter on the 1257 to rebend it for more clearence for the HY2 Hyd. unit. I will be surprised if y'all can't get it with a good puller and good impact wrench. Keep us informed...

[Brockport Bill 2,497]

6 hours ago, sqrlgtr said:

did the induction heat gun get the pulley hub red hot? I have not used mine on any pulleys, but it did get the bolts/nuts I used it on red hot. Also used it to heat up a shifter on the 1257 to rebend it for more clearence for the HY2 Hyd. unit. I will be surprised if y'all can't get it with a good puller and good impact wrench. Keep us informed...

did not get pulley collar red hot - the kit did not come with coil that fit tight to pulley collar so that might have prevented the heat conduction from making red hot ???????

[sqrlgtr 4,154]

5 hours ago, Brockport Bill said:

did not get pulley collar red hot - the kit did not come with coil that fit tight to pulley collar so that might have prevented the heat conduction from making red hot ???????

 

May have had sumin to do with it IDK. I did make a coil out of the extra wire  that came with my kit, now that I think of it that's the only one Ive used. My thinking was making coil a tight fit without it actually touching anything.

[peter lena 10,103]

@Brockport Bill  regularly refer to lubrication , something else I do , is to just regularly add some kroil  , to an up coming service area , that way any related movement , days / weeks out its creeping in , also if  possible pull out  set  screw , for  more  direct start point , typically notice a , creeping film related to  movement, done a lot of that . just the way  I look at a  service issue , pete