Need to remove the crank sprocket on my 1994 Trooper -- 6 cylinder to replace the crank seal. I have tried prying on the sprocket but have not budged it and instead caused several chips to the back flange. Also have tried to remove key out of the key way and have used lots of penetrating oil. Any hints on the removal of the sprocket are they hard to come by/expensive if this one is damaged? Thanks in advance -- Keith

Where are you in Minnesota? I have a shop manual if you do not...

I'm in the Twin Cities Hudson actually -- most instructions say to remove the sprocket without saying more -- the pulley came off with my puller the other cars I've worked on the sprocket just slides out -- not this trooper -- does your manual talk about a special puller or other special instructions?

OK that's a bit far, I am on the west side of the Cities...

Not sure which you mean by "sprocket"...are you referring to the timing belt pulley? If so, the shop manual does not mention any special tools or procedures.

The issue is the cogged gear that slips on the front end of crank shaft once the belt pulley is removed. The timing belt slips onto the cogged gear which has a key way and key. The front crank seal is behind the lower cogged timing gear. It stuck tight.

i know on all of the cars I have worked on including my 90 trooper you have to use a gear puller to pull it off. The gear has such a tight fit that you have to use a puller to get it off. and to get it back on you usually can heat up the gear and pound it on with a hammer and a soft piece of material like wood or a brass rod so it doesn't damage the gear. If it is the timing gear you are talking about, I dont know how many miles your rig has but it is usually a good idea to replace the timing set while you have it all apart.

This sprocket is a slip fit...it slides over the shaft and key....and as you have found, it is very brittle metal. A conventional gear puller may work if the fingers are small enough to get between the flange and the engine...what most guys do is spray the crank with PB Blaster or other penetrant, let it soak, then gently use a wide slim piece of thin metal (a little heavier than flashing)on Opposite sides of the sprocket at the same time and gently and evenly pry it forward..the key is evenly. I have repaired my sprocket using silver solder (just like you the first time I chipped the inner flange)and filed it smooth. Another method and the one I recommend is to put on a heavy glove and pull on the sprocket HARD while wiggling it. If you use the penetrant, it will come off. No need to remove the key....and I would NOT use heat or a hammer on it. Hope this helps. One guys opinion.

Not sure if you're done yet, but I just pulled mine off of an 88 trooper. It wouldn't budge. I used a faucet handle puller. mine is like a slide hammer. I was able to grip the front edge of the timing pulley with it and cranked the center rod and used the slide and it eventually came off.