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One easy method is to clean the pulley and pump shaft. Put the pulley in the kitchen oven at about 250 degrees long enough to come up to temperature. Depending on the pulley material, you can go to much higher temperatures. You couldn't get a steel pulley hot enough to hurt it in a kitchen oven. For every degree you increase the temperature of the pulley, the pulley including the shaft hole, gets larger.

If possible reduce the temperature of the pump shaft. Use ice or a CO2 fire extinguisher. This makes the shaft smaller.

The effect of making the pulley and it's shaft hole larger, and the shaft smaller should place you where the pulley doesn't need to be forced on the shaft

Get the pulley and pump close. Dry the pump shaft. Pick up the pulley with hot pads or heavy gloves and simply slide it on the shaft by hand. This should be one swift, smooth motion and done with out stopping. Every time the pulley touches the pump shaft it will lose heat. and the shaft will gain heat until the pulley stops sliding freely.

The idea of doing this this way is to avoid forcing any part of the pump shaft and maybe damaging the pump.

I once used a charcoal fire and a cast iron dutch oven to install a wheel bearing on my boat trailer while camping. It worked slick.

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Q: How do i Press on a pulley to power steering pump?
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