Bugger, its one thing after another, it appears that the carrier is rusted solid to the splines of the stub axle, most likely all of its 22yrs.

I have sprayed it liberally with spray oil and left to soak, tried to release with 4in 3-leg hub puller tightened to breaking point, whilst heating with heatgun and wacking it with a large rubber mallet. Left to soak & contemplate some more, several more attempts but still no joy. It hasn't budged at all!

Me thinks larger hub puller?
Cut it off and buy a new one?

Any other ideas?

Seems some others had same prob, but no outcomes were posted
viewtopic.php?f=24&t=27693&hilit=sprock ... l&start=10
mmm

Update:
Still stuck fast, jesus, I can't believe its been almost a month on this!

A magnet confirmed the carrier is ally. Keep feeding it with WD40.

Plan A: borrowed 4" puller failed - literally, it sheared one of its leg bolts - chinese cr4p.

Plan B: purchased 7" puller failed - legs too big to use with sprocket in place. Spaced sprocket away from carrier using 6no 35mm steel bolts and fitted puller legs to inside of sprocket. I can see the carrier lugs flexing. Sussed that the sprocket needs to be bolted to the carrier to brace it & prevent it from bending/snapping.

Left puller in place for days. Cooled everthing down for ages with ice cubes and large bag of frozen peas, then used heatgun on carrier. Also shocked with large rubber mallet. Nothing (but I refuse to give in). Kept my spirits up by restoring the whole ss exhaust system to a mirror finish at various interludes.

Plan C: Scronged around some local garages for loan of heavy duty slide hammer, on its way for Friday. Sourced some scrap metal plating, 6mm & 10mm thick! Fitted 6no 100mm long bolts to carrier and secured sprocket with steel nuts. Spent this evening fashioning a piece of steel plate to fit the end of the bolts, await slide hammer to finish it off.

To be continued...

Sounds like a saga... I'd be asking around if someone has a cheap spare.

Yes I had thought of cutting it off, but I would sorta feel like it has beaten me.
Once I degreased the carrier, externally it looks mint so would be a real shame to destroy it just yet.
Sourcing another mint one would probably bring its own issues.

Would suggest you try a penetrating oil like plus gas or rostoff rather than a water displacement spray like wd40. Good luck-hope you win!

Sledgehammer the fuck out of it if you're going to buy a new one anyway

Can you heat it up? Penol is a good penetrating oil.
Cheers
Ian

I was going to suggest the same thing but he already said he'd had a heat gun on it so didn't bother. I had a similar issue with my carrier and i gave it to a friend to sort out (I can't get power down to my garage) and he used heat to get the carrier off.

How about hammering the axle out which will hopefully free up the sprocket carrier as it will have nowhere else to go? obviously remove the gubbins including circlip from the other side first.