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How To Swap A Press Fit Pulley
The Pulley Boys pulley tool is specifically designed for exchanging the press fit pulley on Eaton M90 superchargers. Known applications are 1997-2001 Grand Prix GTP, Bonneville SSEi, Buick Regal GS and Park Avenue Ultra.
Disclaimer: Pulley Boys assumes no responsibility or liability for damage or injuries, which may result from the use or installation of its products. Pulley Boys products are sold without any express or implied warranty or merchantability for any intended purpose.
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| Pulley Tool parts list: |
Additional tools and items required: |
(1) steel top plate
(1) steel back plate
(1) 5/8 main rod
(1) 5/8 nut
(2) 5/8 washers
(3) 3/8 bolts
(3) 3/8 washers
(2) M8 studs
(1) 3/8 x 8" bolt
(1) Anti-seize
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15/16 wrench for the 5/8 nut on main shaft
1/2 socket and ratchet for the main shaft
Additional tools and items recommended:
5/16 wrench for battery terminal
10 mm wrench for fuse box removal
21 mm wrench for breather nut removal
15 mm wrench for tensioning idler pulley
Vise-Grips
Good Year Gatorback belt (not absolutely necessary, but a very good idea). #4060660 for 3.25" and larger pulleys, #4060650 for 3.25 and smaller pulleys.
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Preparation
Begin with a cool engine. Cold overnight is best.
Disconnect the negative terminal from the battery.
Clear the work area by moving necessary components. This includes the radiator reservoir bottle (except for '97-98 GTPs) and the fuse block housing. Full disconnects are not necessary, just move out of the way. Note: the fuse block only has one 10mm nut on the top and the lower half is located within a slot. Simply lift up and it will come loose. Disconnection of one wire connection and fender clip below the fuse box may be necessary.
Remove the breather nut on the end of the supercharger shaft with a 21mm wrench.
Remove the supercharger belt. Tension on the belt is released by turning the 15mm nut on the idler pulley clock-wise.
Important; use a fresh M8 screw and washer for every pulley swap.
Pull the OEM blower pulley
Apply anti-seize to the 8mm stud and install into the end of the 5/8 threaded rod, the 8mm washer and then install the 5/8 rod assembly into the end of the supercharger shaft.
Apply anti-seize to the 5/8-rod assembly where the 5/8 nut will have thread contact during the pull. Install the 5/8 nut and then both of the washers after that. The two washers together, with anti-seize between them, will act as a thrust bearing.
Place the triangular top plate over the 5/8-rod and fasten to the back plate with three 3/8 bolts tightened at an equal length.
Hold the 5/8 rod steady with a 1/2 socket and ratchet while turning the 5/8 nut counter-clockwise against the top plate with a 15/16 wrench, this will remove the pulley. The ratchet handle may be rested on the strut tower with a rag placed under it as to not mar your paint.
The pulley may take quite a bit of force to remove. It is common to hear a pop when the pulley breaks free.
After the pulley removal, the 5/8 rod may be very tight on the supercharger shaft and may be left in place for the installation.
Install the new Pulley Boys blower pulley
If any corrosion is present on the supercharger shaft, use scotch-brite to buff clean.
Coat the bore of the pulley and supercharger shaft with anti-seize. With the 5/8-rod still in place on the supercharger shaft, place the new pulley over the rod, then the triangular plate, and both 5/8 washers followed by the nut. Alternately, the triangular plate may be omitted, but the benefit of using the plate is that it will stop against the end of the supercharger shaft.
As in the pulling configuration, place the 1/2" socket and ratchet on the end of the 5/8 stud with the ratchet handle up against the strut tower. To counteract the rotational force of the puller tool assembly, install the 3/8 x 8" bolt into the side hole of the triangular plate.
Tighten the 5/8 nut, pressing the pulley on to the supercharger shaft, using even steady pressure. Verify that everything is straight and remains properly aligned.
Once the pulley has started on the supercharger shaft, remove the side bolt from the triangular plate to enable ratcheting action for quicker installation.
The pulley is fully installed when the face of the pulley is flush with the end of the supercharger shaft.
Install the new gatorback belt, breather nut, fuse block and negative power cable. Verify that all tooling has been removed from the engine bay.
Pullertool.pdf is available for download and printing with 
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