If it was screwed up I figured it would be too big, not too small. The real problem is I was too gung-ho with honing it out so it wasn't a tight enough fit. I called IW and they are going to hone a new hub when I measure the shaft of the new pump to make sure it fits.

Your supposed to hone it prior to installing?

You aren't supposed to but if you read back a couple pages I was having a hell of a time pressing the pulley on so I had to hone it some to get it on there. I was doing it by hand with a dremel so clearly I did it too much. Just got back from getting a brand new pump (just in case) using the one with the stuck pulley as the core and I got a new Duracell battery from sams for $110 with a 3 year warranty using the 10 year old battery that came with the truck as a core :lol:

Just know that the tighter it is (provided you get it on without fucking everything up), the better it works. It should never be like a slip fit.

Did you ever measure the hub before honing it? What was the interference?

Yea, it measured right at 0.75, as did the hub, so I guess my calipers just plain suck or the hub/shaft wasnt perfectly round.

I was reading the tolerance on some of the cheaper calipers when i was at school and it's up to +or- 0.0015". so you technically can't measure a press fit of about .001" accurately. On my set, the measurement jumps around by about .001". Try using a micrometer to send the dimension to IW if they're turning it based on your dimension.

I have some left over loctitie 640 and primer that goes with it. The sleeve retainer is supposed to add 3 ksi of shear strength. You can use it and send it back to me. They only come in 50ml bottle so I bought it and only used a bit. Let me know.

I already have the new hub waiting for me at home, just need to get off work now! If I am still having issues I may take you up on that!

Awesome! Hopefully you don't need it so we can get some videos soon. Let me know if you do need it and I'll ship it asap.

Call a few of your local auto parts stores and see if they have Permatex 64000.

It's a Hi temp sleeve retaining compound that some auto parts stores carry.