There is a tool kit that you might be able to borrow from an auto parts store that rents or borrows tool. It includes a bearing assembly to reduce the force on the pulling screw.
New pumps and new pulleys usually come with just a screw and nut but they are the correct thread. You're right about not hammering on the pulley as that will damage the pump, but what they were probably referring to was hammering on the bolt. Use the nut to put pressure on the pulley, then tap the bolt lightly to increase the force. Keep tightening the nut as the pulley starts to walk onto the shaft. Even with the special tool, it takes a lot of force to get the pulley onto the shaft so I still tap the pulling bolt. I've had the threaded tool extensions break numerous times if I just relied on the bolt pressure without tapping on it.
In case you aren't aware already, it is critical that the pulley be installed the exact same distance it was before to prevent belt squeal. Chrysler parts come with the appropriate spacer to set the position but they don't fit with some tools. If you're reusing the old pulley, look in the center hole for rust buildup. It will be shiny where the shaft was so you can use that as a witness mark. Install the used pulley just until the end of the shaft touches the beginning of the rusted area.
Sunday, June 5th, 2011 AT 8:49 PM