Stuck fan clutch 5.9 Cummins

Have you tried heating it? You’ll have to be careful, though….

Some auto parts stores rent the removal kit. I bought the air hammer kit and an adapter for a .498 air hammer years ago and haven't looked back. Other than that, if you have a flex shaft pencil grinder that can reach the nut, use a cutting disc, cut a groove just barely into the threads on one or 2 sides and it should pop off there. I try to avoid heat on fan clutches unless I'm replacing the water pump too. Too much heat can damage the water pump seals with a quickness. Some yahoos put loctite on fan clutches so heat may be unavoidable.

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Careful for what? I guess I don’t want to melt the crank sensor anything?

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That and I think fan clutches are often a sealed unit with some viscous goop in them. You don’t want to overheat that or it may burst. They are however, pretty heat tolerant because of their position behind the radiator. If you heat it with a torch, you may want to wrap the actual clutch on a wet rag as a heat sink.

If you want the least headache: bolt a plate to the pulley with 2-4 bolts so it cannot rotate, then use a long wrench (or the Harbor Freight kit if you’ve got good air). That usually does it without wrecking stuff.

My beater is a 3rd gen with 350K on it. Changed mine beginning of the year. I used the fan clutch tool from Geno's. I have a couple buddies with 2nd and 3rd gens so it will get used. Link to Geno's Tool

Yup found that out the hard way. I got too tired to just actually look at it somehow.

In case anyone in the future has this question.