Fan Removal Tool
 

Has anyone built their own cooling fan removal tool, for a E39 BMW. Or...has anyone been successful at removing the fan without using the tool??

I see you posted this already on the BMW side. There isn't much traffic there, unfortunately.

Try Bimmerfest.com. I found alot of great tech support from the E39 guys there when we had our 528.

replacing my water pump - bimmerfest - BMW Forums

I did this a year ago. Used a steel plate, drilled some holes in it and somehow got the fan off.

I just got a peice of flatbar. Try and make somthing fit. A job so simple held by somthing so simple, to confound the simple minded!!

How big is the hub on the fan? Can you post a picture?

For larger fans, I used something called "The Ultimate Puller".
Very simple construction. Someone with a lathe should be able to reproduce it in a smaller form.
Note. If you make a million dollars from this idea, please remember me.;)

Well I tried to make it out of aluminum, no worky, just ripped the holes out, too soft...

Used the BIG screwdriver method, was working them the friggin pully cracked in half....&*%t

Well, that sucks!!!

Can you source another easily?

That's a bummer! I usually left the tool in the box and grabbed the punch (a big punch) and 5lb hammer. Indent one side of the 36mm hex on the next fan clutch if you plan on keeping the vehicle.

I never really cared for the tool.

My pulley broke as well. The dealer still has them in stock because it is a high failure item.