Re: How to remove a woodruff key?
Sometimes the only thing you can do is grind the key out with a dremel. Yamaha marine engines use a carbon steel key for their water pump even in their 'saltwater' series which is notoriously hard to get out because is is always heavily rusted into the driveshaft. You can also drill relieve holes into the key to get some penetrating oil like PB blaster or wd40 working with you along with heat from a mapp gas or oxyacelalene torch if you are going to beat it out. (head around the key to expand the slot, don't head the key)