Cheap and Simple Gear Puller





Introduction: Cheap and Simple Gear Puller

About: I like to build things... except for wiring.. wiring sucks.

This instructables describes and shows how to build a simple gear puller.

If you like to tinker with motors you'll find that a lot of motors from toys and equipment have stubborn pinion gears stuck on the shafts. These can be a pain to remove, and while prying on them or punching them out with a hammer can sometimes work, you risk damaging the motor.

This will show you how to make a very effective gear puller with basic tools and next to no cost.

Step 1: Cutting the Frame

You will need something to act as the frame for the puller. Square metal tubing works great for this as long as the wall is thick enough to tap threads.

I used a piece of 1" square steel tubing with 0.1" wall thickness. I cut it to a length of 0.75" with a hacksaw, it doesn't have to be pretty.

Step 2: Drill the Screw Hole

Drill a pilot hole in the center of the tube, going completely through the tube. This will ensure that everything lines up nicely in the end.

Since I'm using a #10-32 screw for my puller I drilled a 5/32 hole in the top wall and tapped threads into it.

Step 3: Cutting the Shaft Slot.

You will have to add a slot going to the pilot hole in the bottom plate to let the motor shaft in. You can make the slot whatever size you like but it should be bigger than the motor shaft yet smaller than the gear you intend to pull.

There are a variety of ways to do this. Hacksaw, dremel cutting disks, drilling more holes in a path...

Step 4: Modifying the Screw

It is likely that the screw you want to use will be too big to push out the gear you want to take off, a pin will need to be added on the end of the screw for this.

Center the hole the best you can on the end of the screw, a 1/16" is a good size to use as most motor shafts are not that small. You should drill at least a 1/4"-1/2" down.

Step 5: Adding the Pin

You will a pin that is small and very hard so that it will not bend when it is pushing the motor shaft.

I just used a old dull 1/16" drill bit which I put in a vice and tapped it with a hammer to snap it. Eye protection is a good idea just in case.

Put the broken bit into the screw hole and glue it in place. Feel free to use a real pin if its available though.

Step 6: Assemble It and Test It Out!

Thats about it, put the screw into the frame, slide a motor into place and tighten the screw until the motor is safely pushed out of the gear.

Step 7: Gear Pushing

If you need to push a gear back on to a shaft, you can use the same concept with a bigger sized puller.



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    48 Discussions

     thnx for the idea once again i did this for a mechanical practical were i had to make one but it never occured that i can make one for my personal use lol

    Great idea, now I'm burning my hammer, I won't use it any more.

    it works on the same principle that bicycle chain breaker tools do -small amounts of force applied over a long period of time have lots of strength - you can drill holes in pennies with chain breakers

    Clever idea, should work well up to it's limitations, all tools have them, pleas don't read that as a negative. Great instructable showing others how to do it. Well worth it's inclusion in the weekly email bulletin. A rare 5 rating from myself.

    Awesome mini puller! I made something similar years ago, except I just drilled a straight hole and tacked a nut onto a 4x4 square tubing, darn it I should I threaded the tubing instead! :D

    2 replies

    Depends on your tool kit. If you have a tap and die set, then use it. Otherwise, your solution is a good alternative!

    No tap or welder? Simply put a nut on the underside. Adds a level of awkwardness. But it may convince to the buy a tap handle and tap, to begin equipping your shop. Actually if you can get a good tack weld without altering the properties if the nut, the thread in the nut will last way longer than tapped in the tubing. Then again if you get the tap you you can simply make a new tool, when needed.

    a bench vise works well for that job, for small parts. For a dedicated tool for the job HF has their 1 T. versicle press on sale a lot.

    You can use the same idea as a pusher, it just has to be bigger. I won't make an instructable as it would be near identical but it would work like this:


    Neat. You could add it in as step 7 rather than make a separate instructable? L

    tubular(or simply tubing) works. When you go to the machine shop to buy the stuff you ask for certain size of rectangular or square tubing, or round if you need that. Go ahead and ask for boxular, you may put a grin on the face of the staff for the rest of the day. I wouldn't be surprised if they took to calling it boxular within their shop for a while. Tradesmen can be funny in that way. Nope according to the urban dictionary boxular is already taken

    this gear puller is a good design .I look for new pullers to make all the time ,as i work in the mechanical trade. Thanks

    For us model railroaders, such a gear puller is available commercially but cost more than a few bucks. Nice to see a home made copy that looks identical and seems to function the same.