1: Use A Pilot Bearing Removal Tool
The puller tool inserts into the ID of the pilot bushing or bearing and expands as the tool is tightened down, theoretically obtaining a good hold onto the bushing/bearing from its center. Then, the shaft is tightened, forcing the bushing/bearing out of the crankshaft bore.
2: Hydraulic Force
More often than not, this is our immediate go-to way of removing either a stuck pilot bushing or stuck pilot bearing. First, grab a wooden dowel, steel rod, or what we normally use, a pilot bushing/bearing alignment tool that tightly fits inside the ID of the pilot bushing/bearing. Then, fill the cavity behind the bushing/bearing with grease.
All you need to do is insert the dowel, rod, or tool into the bore of the pilot bushing/bearing and give it a firm rap with a hammer. The hydraulic action will force the bearing out easier than you’d expect. In extreme cases where the bushing/bearing shell is deep and the press-fit tolerance is on the right side, you may need to refill the cavity with grease once or twice before it comes out.
3: Cut And Chisel
We consider this a method of last resort when all else has failed. The reason is the potential for damage to the engine crankshaft. This method works equally well with either a bronze pilot bushing or a steel pilot bearing, but you do need to be extra careful with the bearing to ensure you don’t cut too deeply and damage the crankshaft.
Using a rotary cutting disc is the easiest way. Carefully cut a deep divot nearly the entire way through. It’s not necessary to cut all the way through, though, as this increases the potential for damage to the crankshaft.
Using a sharp, flat chisel, firmly strike the bushing or bearing shell. If you’ve cut deeply enough, the busing or bearing shell will crack, relieving the press-fit in the crankshaft bore.
Then it’s just a matter of removing the pilot bushing or bearing with your hands and reinstalling a new one.