Problem: My blower motor shaft is stuck to the blower wheel! How do I get the blower motor out to replace it?
Answer: I have had this problem before many times when I was trying to replace furnace blower motors! The blower wheel is stuck to the blower motor shaft and in order to replace the blower motor, you need to get the blower wheel separated from the blower motor! Here are the steps that I used many times to remove the blower motor from the blower wheel. We have two really good YouTube videos below made by Word of Advice TV that show how to remove a stubborn blower wheel from the blower motor and another video made by HVAC Parts and More that shows How to Replace a blower motor, wheel, and blower housing on a Lennox furnace. Many thanks to Word of Advice TV and HVAC Parts and More for making these excellent videos. Here are the steps that I use to remove the blower wheel from the motor. When I used these steps I never had to use a mechanical wheel puller.
(1) Loosened the set screw and oil the shaft with penetrating oil.
(2) Sand the shaft with light emery cloth sandpaper. Make sure there is no rust or high metal gouges in the motor shaft. If there are high spots or marks in the motor shaft then a file might be needed to file the high spots down on the motor shaft.
(3) Remove the usually 3 of 4 motor mounting bolts that are holding the motor to the blower housing.
(4) Sit in a chair and open my legs and knees far apart so the motor can fall to the ground when the motor becomes free from the motor shaft. If you do not feel comfortable with placing the motor housing in between your legs then place the blower housing between two sawhorses so that the motor can fall out after you beat the shaft through the blower wheel hole. Place a pillow or something soft so you do not damage the motor brackets or damage the floor when the motor comes loose from the wheel.
(5) Get a 3/8″ long extension and a hammer to beat the motor shaft out of the blower wheel. The 3/8″ extension will fit through the blower wheel shaft hole. The motor should fall out. Be careful not to get hit with the falling blower motor. It can be hard on the toes and legs! If the blower motor does not come loose from the blower wheel after several hits then you might need to purchase a blower wheel puller like in the YouTube video. If the shaft on the motor becomes mushroomed then you will need to file the mushroom down with a file. I hope you have good luck and can get it off. If you have any questions or recommendations then please email us anytime or comment below. Our email is firstname.lastname@example.org. We would love to try and help you out!