What are you guys using to remove & install these pulleys? I've never had any trouble at all using the correct pulley remover & installer tool. I have a Snap-on & an OTC set that works great. You can't just hammer them on or off. They'll get damaged every time. If you use the correct tool to remove & install it it should work much easier. Harbor Freight even sell a set that only costs like $20.
HTH.