Replace blower motor, how to
 

I have an '85 300D with a bad blower motor.

Althought it is in desparate need of new brushes, the real culprit is a broken brush connector braid. It looks like a real pain in the butt to change brushes, and I don't see them listed as parts anyway. So, unless someone knows of a relatively painless way to replace the motor brushes, I'm looking at replacing the motor. But, there is one thing that yet baffles me.

How in the world does one separate the fan from the motor? Just pull real hard??

Thanks,
Terry

Isn't there an e-clip or C-clip on the shaft? That is a usual method of holding them on. Look where the shaft and the motor connect VERY carefully, perhaps with a magnifying glass. It could be a force-fit, but I doubt it.

removing plastic fan from blower motor
 

By coincidence, I just removed the plastic "squirrel cage" fan from the blower motor for my 1991 420SEL (W126), last night. In the W126 case, anyway, the fan is just a press fit onto the metal shaft of the motor. There is a hole in the center of the plastic cylinder that fits over the end of the motor shaft. The technique I used was to support the plastic fan on it's outer perimeter, with the motor dangling over an open space. Then I used a hammer and a Phillips-head screwdriver (a nail set would also serve) to hit the end of the motor shaft (through the hole in the center hub of the plastic fan). I also used a couple drops of penatrating oil, but it's not clear if this really made a difference.

The key to not breaking the plastic fan is to support it on as broad an area as possible. In my case, I had an empty gallon paint can laying around, and the rim of it matched the size of the fan wheel pretty well, supporting it all around its perimeter. The motor was hanging down inside the can. You have to pound on it pretty hard, and nothing happens for a while, until it finally pops free. Other posts have talked about positioning two tables close to each other to support the fan - another variant of this would be to use a Black and Decker "workmate" portable bench, where you can adjust the size of the opening between the two halves of the work surface. Getting the fan off the motor saves about a $100, but if worse comes to worse and you break the fan in the process, you can always pay the extra money for a motor with fan assembly.

Bob Schleicher
1991 420SEL, 172,000 miles

Go to a shop that does electric motor repair. They will have a wide assortment of generic brushes with braid attached. Hard to imagine one of them wouldn't fit. Typical price <$5/pair.

Enjoy,