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There is no reason that pulley should fail, I have had no issues with mine at all, it ether did not get tightened enough or the shaft was damaged the first time it was put on loose.

I don't but it's just a personal decision, sometimes the washer expands and tries to push out from under the nut, I am still in shock at how good the shaft looks. How does the pulley fit without the key in it?? any slop?

What is the model and ser number of your truck?

If that was the case then the pulley defiantly was not tightened up enough, it should be TIGHT against the shoulder on the alt side of the shaft, this pic shows the side that should go in against the shoulder. If it needed to come out to align with the belts you had the wrong pulley on it, this...

I have removed tons of them, I have never had one I could not remove with a chisel or a punch, it is in a half moon hole ether way you move it it will come out.

pry bar

Use a small chisel and lay it flat on the shaft in front of the key, as you try to knock the key back it will roll out of the shaft. It looks like a 3/4" washer might work the specs call for a .766-.797 ID and a 1.172-1.203" OD, by .0478 thick, most 3/4" washers are a little over size. You might...

The key is no good, I am surprised at how good the shaft looks, the pulley must be much softer, it looks like you just did not get the pulley tight enough. I ordered 4 keys off of fleybay just to have stock, they will be here early next week if you want drop me a PM with your address and I will...

That pulley listed has a different offset than the ones we are running, I assume that is because of a different serpentine belt setup on the earlier trucks under 197K serial number. but they did build a pot load with solid pulleys.

This 200A serpentine application shows the solid pulley but it uses a key

That pulley is keyed and the shaft in the TM looks like it is keyed and shows a key,, I cannot remember now if I have a key on mine or not.

I have been running one but for only about 3K with no problems, can't see how a little rust would hurt, you did clean the bore and stuff yes?

If that is the one you bought then it is a solid pulley and the nut did not get tight enough allowing the pulley to spin on the shaft, if that is a 400A alt I don't think they were ever intended to have a solid pulley way too much rotating mass.

It sure does not look like it, I have been wrong before,,,if the center of the hub is also moving on the shaft then the shaft is damaged to the point the pulley will not come off as the shaft is straight with no taper or keyway, again I could be wrong... EDIT, I am wrong... that shaft does have...

That pulley has an overrunning clutch in it that the bearings have gone south in, will likely need to use a puller to remove. EDIT, I was wrong!