Trouble pulling AC compressor clutch pulley - suggestions?

Hello TacomaWorld!!

Short time Tacoma owner (since Dec '17), long time Taco lover and reader of TW. I have a 2010 TRD Sport Double Cab with ~140,000 km on it - yes I'm in Canada (the land of expensive parts).

My AC compressor clutch started the squeal of death this summer, so I took a crack at replacing it myself. I checked that compressor still turned (it does) and bought a new clutch & hub off ebay and started replacement last night. Things were going very well - hub came off and showed burnt ball of rubber similar to other compressor clutch failures. Getting the snap ring off that holds the pulley on was challenging - it was really wedged in there and didn't want to let go but finally came off after some swearing. However the pulley is very attached and doesn't want to budge! In replacement videos it usually comes off by hand, so I'm not sure if there's some rubber in there or what, but it is stuck!! The pulley turns freely but the bearing inner race seems almost welded to the shaft.

I have tried hitting it with WD40 and liquid wrench to no avail. Struggling to think of ways to get it off without pulling the compressor and going down the path of a full AC recharge. Best idea I have is to disconnect compressor from block but leave the refrigerant lines on, hopefully I could maybe get a bearing puller onto the pulley from there... Before I go down this path wanted to check if TW had any other smart ideas.

I am hesitant to use a torch on it as I don't want to cook any seals on the compressor. Is it even worth going forward with a clutch replacement only or is this a sign that I should bite the bullet and go to full compressor replacement and AC vacuum and recharge? I'd likely get a shop to do this job given that I'd need to get it there just to drain the AC fluid.

Thoughts or suggestions? Appreciate the collective wisdom on here, it has been a great resource so far!!

 

Was the first post in this thread one of your reads?

https://www.tacomaworld.com/threads/ac-clutch-failure-how-to-fix-blinking-light-squealing.448009/

Looks like there is only one bolt to remove. When you speak of snap ring, it makes me think you may be going too deep, and trying to remove the pulley?

 

Yes that was one of my reads; also went further into other threads and videos that did the whole pulley and coil. (https://www.tacomaworld.com/threads/ac-compressor-clutch-replacement.345382/page-2)

Guess I forgot about possibly doing the hub only - figured I'd swap it all since the new bit I bought had it all. I suppose I could just throw the snap ring back on and the new hub face plate and see if that works. Any reason not to now that I have liberally applied WD40 to the bearing? (possibly got some on the coil too)

 

I think it will be fine. And it sounds like you had the 'rubber' failure too.

WD 40 is great for removal of pine sap and road tar, but it's neither a very good lubricant or penetrant.

You might spray the area with some electronic cleaner. It likely would quickly remove any residual WD40 and it evaps fast. Even compressed air wouldn't hurt in removing residual liquid.

Let us know how it goes.

 

Slapped the new hub on there, set the spacing with a feeler gauge, and put everything back together last night. Boom - cold A/C that doesn't squeal!

Thanks for the suggestion Bill - makes me feel dumb for not thinking of it myself!! Hopefully the new hub lasts another 130,000 km and I never have to pull off that pulley in the life of the truck; if so I will be a happy camper!