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Originally Posted by SarahB
but don't, under any circumstances, try the Dremel technique. We've already had to replace two motors because of it.
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What Sarah fails to mention is that the motors were not ruined as a result of grinding the gears. The motors were dropped long after they had thier pinions removed, and the brushes broke. As far as pressing, it is by far the easier and better way to remove the pinion, however if you do not have access in any way to a press and still need to remove the pinion, my method does work. By dremeling, I
did not use a cutting wheel, rather a grinding stone. See the details in the thread that Sarah reffered you to, but the gist is that the hardend steel of the pinion is becomes brittle when it is very thin. By grinding it down to a very thin layer between it and the shaft, just tightening the gear in a vice should cause the gear to crack in half and fall off of the shaft. PM me if you would like some more details.
-Rc