How to Remove Generator From Engine Shaft [Complete Guide]

Removing a generator from an engine shaft is a task that may be required when performing repairs or maintenance on your engine.

 This process, while seeming complex initially, can be handled quite efficiently with the right tools and understanding. 

In this guide, we’ll break down the steps involved, making it a simple and straightforward task for both seasoned mechanics and novice do-it-yourself enthusiasts.

How to Remove Generator From Engine Shaft

How to Remove Generator From Engine Shaft

1 . Use of a Puller

The use of a puller simplifies the process of separating the generator from the engine shaft. 

A puller is a specialized tool designed to exert pressure on the generator, facilitating its removal without causing any damage to the engine components. 

The first step is to secure the puller over the generator, ensuring that the center bolt is aligned with the generator shaft’s end. Tighten the puller’s bolts gradually and evenly to apply steady pressure. 

As you turn the puller’s handle, the generator will begin to disengage from the shaft. Be sure to monitor the process closely to avoid any potential damage. This method is reliable, effective, and can save a lot of time when performed correctly.

2 . Application of Penetrating Oil

Penetrating oil, often referred to as a penetrating fluid, can be a game-changer when you’re trying to remove a generator from an engine shaft.

 It has the ability to seep into the cracks and crevices between the generator and the engine shaft, breaking down rust and corrosion that may bind the two components together. 

To use this method, first, apply the penetrating oil liberally around the area where the generator meets the shaft. Allow it to soak for at least fifteen minutes – this gives the oil sufficient time to penetrate and loosen the rust or corrosion.

 After the soak time, attempt to twist or pull the generator away from the shaft. You might find that the generator now easily slides off the shaft. Remember, patience is key.

 If the generator doesn’t come off on the first try, reapply the oil and wait again before making another attempt. This method requires less mechanical force than using a puller, reducing the risk of damage to the engine components.

3 . Warming the Shaft Area

Sometimes, applying gentle and controlled heat to the shaft area can aid in removing the generator. Heat causes metal to expand, and this expansion can break the bond between the generator and the shaft.

 To utilize this method, use a propane torch or similar heat source, and evenly apply heat around the shaft where it adjoins the generator. Avoid overheating any single spot to prevent damage. 

Once the area is adequately warmed, but not too hot to touch, attempt to twist or pull the generator off the shaft. Be sure to use protective gloves to prevent burns.

 Remember to always use caution when applying heat, and keep a fire extinguisher nearby for safety. This method can be very effective, especially when combined with the use of penetrating oil.

4 . Using a Hammer and Chisel

The “Hammer and Chisel” method is a traditional approach that can be employed when dealing with stubborn generators. 

This method, though relatively simple, requires caution to avoid damaging the engine shaft or generator. To begin, position the chisel at the joint where the generator and shaft meet. 

Strike the handle of the chisel gently with the hammer, aiming to create a wedge between the two components.

 The strikes should be firm, but controlled, to ensure that you apply sufficient force to break the bond without causing any damage. As the chisel begins to penetrate the joint, the generator should start to move away from the shaft. 

This progress indicates that the bond is breaking, allowing the generator to be removed. However, it’s vital to avoid forcefully hammering the chisel, as this could potentially cause more harm than good. 

Proceed slowly and patiently, allowing the chisel to gradually disengage the generator from the shaft.

5 . Employing a Two-Jaw Gear Puller

Employing a Two-Jaw Gear Puller is another effective method to remove a generator from an engine shaft.

 This tool, as the name suggests, has two jaws that grip the generator. To use this tool, first, position its jaws around the generator, making sure they have a firm grip on the part. 

You then turn the handle, which in turn applies pressure on the generator. As you continue turning, the generator will gradually disengage from the shaft.

 It’s crucial with this method to apply steady pressure, rather than forcing it all at once. Forcing it may lead to damage to either the generator or the shaft.

Once the generator is successfully disengaged, it can be pulled away from the shaft with ease. This method, while similar to using a standard puller, offers greater control and is often more comfortable to use due to the grip provided by the two jaws. 

If performed correctly, it’s a straightforward and effective way to remove a generator from an engine shaft. Remember, slow and steady wins the race when it comes to employing a Two-Jaw Gear Puller.

6 . Utilizing a Three-Jaw Gear Puller

Utilizing a Three-Jaw Gear Puller is yet another beneficial tool for removing a generator from an engine shaft.

 Unlike the Two-Jaw version, the Three-Jaw Gear Puller provides a more balanced and secure grip on the generator due to its three-point contact. 

To commence with this method, position the three jaws of the tool evenly around the circumference of the generator. Ensure the jaws securely grip the generator and then begin to slowly turn the handle.

 This action applies pressure, causing the generator to gradually disengage from the shaft. The beauty of the Three-Jaw Gear Puller lies in its uniform distribution of pressure, avoiding any undue stress on one particular area that could lead to damage.

 As always, patience is a virtue here. A slow, steady pull reduces the risk of any harm to your engine or generator.

 On successful application, the generator should easily slide off the shaft, making the Three-Jaw Gear Puller a reliable, safe, and efficient method for this task.


In conclusion, removing a generator from an engine shaft might seem like a daunting task, but with the right tools and techniques, it’s completely manageable.

From the application of penetrating oil, warming the shaft area, using a hammer and chisel, to employing a Two-Jaw or Three-Jaw Gear Puller, each method has its own strengths and scenarios where it proves to be the most effective. 

Remember, patience and caution are crucial to avoid any potential damage to the engine shaft or generator. With these methods in your arsenal, you should be well-equipped to handle the task successfully.


Can I use any type of oil for the penetrating oil method?

A1: While you could technically use any oil, it’s advisable to use a specialized penetrating oil for the best results.

Is it safe to use a propane torch for the warming method?

Yes, as long as you handle it carefully, avoid overheating any one spot, and keep a fire extinguisher nearby.

What should I do if the Hammer and Chisel method doesn’t work?

If the Hammer and Chisel method doesn’t work, you can try a gear puller or repeat one of the earlier methods mentioned.

Which is better: a Two-Jaw Gear Puller or a Three-Jaw Gear Puller?

Both have their merits, but the Three-Jaw Gear Puller typically provides a more balanced and secure grip.

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