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Ricardo Hohl
Ricardo Hohl, Master Certified Tech
Category: Dodge
Satisfied Customers: 4265
Experience:  Automotive instructor at Porter and Chester institute
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2004 dodge truck: pull..crankshaft..2500 cummins diesel..pulley

Resolved Question:

how to pull a crankshaft gear off the crankshaft on a 2004 dodge truck 2500 cummins diesel and what type of pulley do i need to pull the gear off the crankshaft. the motor is a 5.9 cummins diesel
Submitted: 8 years ago.
Category: Dodge
Expert:  Ricardo Hohl replied 8 years ago.
there is 2 ways sense you ones remove you can not reinstall. follow this procedure i am sending. you may have to split the gear to remove
Service and Repair



  1. Remove the gear housing cover.
  2. Remove the crank gear using a heavy duty puller.
  3. Split the gear and remove it from the crankshaft.


  1. Remove all burrs and make sure the gear surface on the end of the crankshaft is smooth.

  1. If removed, install a new alignment pin. Drive the pin in using a ball-peen hammer, leaving it protruding 1.0 mm (0.039 in.) to 1.5 mm (0.059 in.) above the crankshaft (Fig. 67). WARNING: WEAR PROTECTIVE GLOVES TO PREVENT INJURY. CAUTION: DO NOT heat the gear longer than 45 minutes.
  2. Heat the crankshaft gear for 45 minutes at a temperature of 149 °C (300 °F) . Do not use torch, gear failure will occur.
  3. Apply a thin coat of lubricant to the nose of the crankshaft.
  4. Position the gear with the timing mark out and install it on the crankshaft using the alignment pin. Make sure the gear contacts the shoulder.



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