They will most often "pop" quite loud when it first gives, and make you think you broke something, but after that it'll come right off. To reinstall, I apply some anti-sieze on the crankshaft, install the threaded rod also with some anti-sieze on the threads, and use a couple washers with grease between them to act as a thrust bearing in between the plate and the nut. I always use a standard box end wrench with another of similar size hooked to it to act as a cheater to pull the pulley back on the crankshaft. Takes a bit of time going round and round to pull it on, but never had an issue and certainly a lot quieter than an impact.
I also worry about stripping the threads on the rod. I have noticed it warming up, but never too hot to grab ahold of and never ruined any threads.
Here is a pic of one going back on from a DSCF a few years ago. You can see the washers between the plate and nut, and the anti-sieze on the threaded rod. I think I removed and reinstalled 5 during the two days of that fest this same way.
