I've stripped one of the threaded holes on the pump flange that holds the pulley on. Am I forced into replacing the pump or is it possible to pull the flange off and helicoil the boogered thread? My fault completely as I forgot to torque the bolts.

 

I haven’t done this, but I would certainly try a helicoil if it was mine.

 

For very sure, the triangular flange slides out of the pump shaft without removing the pump. Try prying out with some bar. A weld blob can deposit enough meat to re-thread.
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I would take the pump off, you need a press to get that flange off, and even then I have broken an ear off before.,

 

Sounds like unbalance is not an issue? I would have thought so - so that’s nice.
When you take pump out to bench, could you feasibly get the thing in a vice to do your doctoring? The Whole pump is rather small

 

I'd helicoil in place, even if it meant sacrificing a helicoil tap to make a bottoming tap. Shouldn't be too bad. If there's not clearance to knock the tang out the back, you can also just reverse rotate with the insertion tool to break the helicoil tang off.

 

Helicoil in place is probably possible but the issue would be drilling the hole out to right size for the heilcoil, difficult without a right angle drill. You did not mention but I assume this happened because you replaced the pump? Hopefully you left that stupid stud (#12) off when you went back (I never put them back on)? If you did it is only about 20 mins to get the pump off.

 

You can use a puller to remove the flange.

 

I’m going to try to drill and helicoil in place. I’ll borrow a right angle drill from work and see if I have enough clearance to drill and tap. If that fails I’ll try to pull the flange off and then worry about pressing it back on

 

Have you ever seen the flange having moved out some on the shaft causing misalignment of the pulley? if so, what method did you use to
put it back into the correct location on the shaft?