I tried with a 5/32" punch but it still doesnt want to seem to come out. I am afraid if I hammer too hard it might bend the shaft. I have tried lubing the roll pin with WD-40 but it hasnt helped. Any other ideas much appreciated.

Sunny

Make sure the motor housing is still attached. I.E. still slid over the shaft. You may want to put the punch in a set of vice grips, otherwise make sure it is positioned perfectly centered on the roll pin and smack the crap out of it with a hammer. As long as the motor housing is still attached you won't do any damage to the shaft.

doorguy06,

Thanks very much. I had trouble posting back yesterday. I took the gear/sprocket assembly off. Then I had to cut part of the plastic off with a dremel tool to have better access to the roll pin. Then I could hammer it out by holding it in a vice. The roll pin was really tight. Put the new gear in, lubed it well. The garage door is working fine now

Thank you,

Sunny