How to Properly Use a Gear Puller

Start by choosing the right puller and jaws

Before you touch a wrench, measure the part you want to remove. You need to know how wide it is and how far back the jaws must reach to hook behind it. If the jaws cannot open wide enough or reach far enough, the tool will not grip safely.

Our best gear puller page lists spread and reach for each model so you can compare them with your measurements. For example, the Orion Motor Tech set includes four sizes with maximum spreads of 3, 4, 6 and 8 inches. The DURATECH puller opens to 3 inches with a 3.56 inch reach, which suits small gears and pulleys.

Pick a puller with a capacity rating above what you expect to need. Rust and long service time make parts harder to remove than they look.

Compare common puller types

The drive type changes how you work. A screw puller turns with a wrench or ratchet. A hydraulic puller uses a pump handle and a ram to build force. The table below uses figures from the products on our comparison page.

How to use a 2-jaw or 3-jaw gear puller step by step

The steps are the same for most screw pullers. Take your time with the setup, because most mistakes happen before you apply any force.

• Wear safety glasses. Check that the jaws and screw are straight and not cracked or bent.
• Clean the area and spray a penetrating oil on the joint between the part and the shaft if it is rusty. Give it time to soak in.
• Back the center screw out so the jaws have room to open.
• Hook the jaw tips behind the part, on a solid edge such as the back of a gear or hub. Space the jaws evenly around the part.
• Set the tip of the center screw on the shaft end, centered. Many shafts have a small center hole for this. Use a thick plate or cap on the shaft end if you want to protect the threads.
• Make sure the puller sits square to the shaft. A tilted puller will slip or bend.
• Turn the screw with a wrench or ratchet, slowly and steadily. Watch that the jaws stay seated as the part begins to move.
• Once the part is free, back off the screw and slide it off by hand.

Two jaws or three?

Three jaws form a triangle and spread force evenly, which is why they grip steadier on larger or heavier parts. Two jaws fit into tighter spots and suit small bearings and gears. If you use two jaws, place them directly opposite each other so the pull stays balanced.

Reversible jaws let you pull from the outside of a part or from inside a bore. To switch, flip the jaws and reseat them in the holder. The Orion Motor Tech 6 inch and 8 inch pullers have dual fixing holes that give four configurations. The CARVALAX kit adds spread-locking balls that hold the jaws open while you line up the tool.

How to use a hydraulic gear puller

A hydraulic puller works on the same idea, but the ram does the pushing. Set the jaws behind the part, center the ram on the shaft, and pump the handle to extend the ram. The VEVOR models list a 15 ton rating and can work horizontally or vertically, so you can use them on parts facing different directions.

Pump slowly and check the alignment after the first few strokes. If the jaws begin to shift, release the pressure and reset them. When the part comes free, use the release valve to retract the ram in a controlled way.

Hydraulic units are heavier than screw pullers. The VEVOR models listed on our page weigh 17 lb and 25 lb, so plan how you will support the tool before you start pumping.

How to remove a pulley with a gear puller

For a pulley, hook the jaws behind the hub or the back edge of the rim, wherever the metal is thickest. Avoid thin flanges, because they can bend or crack under load. Many pulleys are held by a key or a set screw, so remove those first, or the pulley will not slide off.

Center the screw on the shaft end and tighten slowly. If the pulley resists, stop and add penetrating oil. A light tap on the end of the screw with a hammer can help break rust loose, but wear eye protection and do not strike the jaws.

If the pulley still will not move, a larger puller may be the better choice. Compare options on our gear puller comparison before forcing a tool beyond its rating.

Safety notes

Pullers store a lot of force. If a jaw slips, the tool or the part can fly off. Wear safety glasses at all times, and keep your face and hands out of the line of pull.

Never exceed the puller's rated capacity. Stop if you see bending or hear cracking. Do not heat a part with a torch unless you know the part and the surrounding materials can handle it, and keep flammable items away if you do. Support any heavy part you are removing so it cannot drop on your feet.

Frequently asked questions

Can I use a gear puller on a bearing?

Yes, if the jaws can hook behind the inner race or a solid edge. Pulling on the outer race of a bearing can damage it, so check where you are gripping.

What if the puller keeps slipping off?

Release the pressure and reset it. Check that the jaws are evenly spaced, the tips are seated on a solid edge, and the screw is centered on the shaft. A different jaw size or a three-jaw setup may grip better.

Should I use an impact wrench on a gear puller?

It is best to turn the screw by hand with a wrench or ratchet. Steady pressure gives you control, while impact force can slip the jaws or damage the tool.

How do I know when to switch to a hydraulic puller?

If a screw puller is near its limit or the part will not move after oil and steady pressure, a hydraulic puller with a higher rating is the safer choice.