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There was no need to remove the spacer. It was just a simple pulley replacement. As to the front seal, no leaks, so mine was fine.
You are the third person (to include me) that was able to remove the pulley with out issue. So maybe later flathead pulleys were not an issue, by design. If you are worried about it, a bit of loctite could be used on the bolt threads.
Nothing like have a donor car, with it installed, rather than relying on someone to provide all the parts from a car.
Any issuestheh the installation of the crush hex nut?