A lot of South Bend shafts are somewhat soft. The metal can mushroom, or ding pretty easy. I'd recommend screwing the nut flush on threads whichever way you go, atleast until you get the gear moved enough.
A press is dead useful for so many tasks. Really, I'd say you got to have one. I'm not a huge Harbor freight kind of guy, but they have suitable presses that will cover many future tasks pretty cheap. They have some larger presses, but a 12 ton-er will do the grand majority of your needs and not eat floor space for $140:
12 Ton Shop Press
point taken about soft shaft and threads, I NEVER hit the top of a thread with a hammer. And I've got a full range of soft head types - rawhide, plastic, brass, rubber and wood mallets.
"Really, I'd say you got to have one" Dude, I know you're out there the wide open spaces of Texas and probably have a lovely 2000sqft shop, but here in LA real estate is at a premium. I've got too much stuff and I'm trying to downsize into retirement, ie: 'how nay of these drill presses do I really need?
(Either that or move). 12 ton is too big for the kind of stuff I imagine doing but I get it, I may have to get me a smaller benchtop model I can shove on a shelf.
I do shop at HF, with some discretion. My rule is - if I need it for a once a year job, ok. If it'll be in my hands weekly, get the good stuff.
Process - as I understand it, the gear (obviously) comes off the front, and the shaft pushed out the back. So if I knock the nut on the thread with a soft hammer, I will push the shaft 'back' which will push the gear 'forward' along the shaft and key? If the gear doesn't come off right away, I could then push the shaft back in, opening a space between gear and backplate, so I could get a gear puller in there?
thanks for your time (all)
A