God, I scr**ed that up. Hole in my PS pulley

Two days ago I replaced my steering pump. The pulley tool i rented at autozone lacked the right size for my pump so I tapped it on with a hammer. Last night I rented a tool set from Advance auto and it had everything I needed. I was so happy that I finally found the right tool, I overtightened my pulley. The car delayed starting and was smoking as the pulley rubbed the outside of the steering pump. In order to fit the tool on and pull the pulley away a little I would have to redo all of the work I had just done regarding the engine mounts and pump removal. Another 4 hours. I decided to get my heavy screwdriver in between and force the pulley away a little.

At first it seemed the pulley moved but then i pushed again an a chunch of the pulley cracked away and broke off. OMFG. Of course I was a little unhappy. Now what. It seems to be working fine without the chunck in place but I am worried that the pulley imbalance is going to have really bad effect on the Power Steering Pump Bearing. Does anyone have experience with a pulley missing a golf ball size chunk?

I just drilled a hole (14mm) in my PS pulley in order to gain access to mounting bolts. Doesn't seem to be hurting it at all. HOwever if your is cracked you are probably going to experience a failure at a most inconvient time. The pulley is made out of powered metal and I guess it doesn't like cracks.

Your making the power steering pump removal much harder than it is. One bolt will remove the mounting bracket and pump. Don't try to remove pulley or replace pulley while it is on the car. I posted instructions in a previous reply.

Well, that pulley didnt last to long. My wife lost steering and figured it was the pump acting up today while i was at work. She drove for about 45 min with an empty tank before she noticed that the DIC was blinking 'charge system'. Well no one has the pulley till tommorow so I will find out if the pump can be easily removed by this bolt in the back when I take the train to brockton 40 min away because of course the thing didn't die in my driveway. I should have fixed this last week.