How to replace remove motor and replace spur gear on Power Gear Kwikee RPE slideout (P/N 1010002007).
1) extend slide fully
2) Jack the slide inner rail (part 2) (I used a post jack from Home Depot ($90)). The slide weighs a lot, so use something substantial (i.e. a 2x4 is insufficient). Properly jacked, the plastic roller (part 15) should spin freely. Place the jack as close to the rig as possible and use a piece of wood to protect the rail teeth.
3) Remove the inspection plates around the wheel well. You may have better access if you keep the air bags inflated.
4) Remove the 8 bolts on the motor side (parts 9 & 25) and pull out the supporting plate (part 23).
5) Pull the hitch pin clip from the bearing side (part 24)
6) Slide out the inner and outer bearings and the motor should slide down and out from the frame. If successful, skip to step 8. If the bearings won't move, continue.
6) My inner bearing was rusted to the shaft so I needed to punch out the coil pin (part 27) to slide off the hex coupler
7) Use a small bearing puller to pull the inner step bearing (part 14). I used this one from Amazon (Amerbm Two Jaw Bearing Puller Remover 30mm - 90mm Adjustable Puller Tool for Special Design for Narrow Spaces Removal Small Bearing or Gears), but any small puller should work. I did need to put a vice grip around the puller teeth to keep them from slipping off. There is not much room to work with, so good luck.
8) Disconnect the two electrical plugs.
9) Once out of the frame, remove the outer cotter pin (part 20) and slide the spur gear off. Again, my spur gear was rusted to the shaft and I needed to take it to a machine shop to pull it with a hydraulic press (my puller and 18" wrench was insufficient).
10) Remove the woodruff key (part 17). You can get a new one at almost any auto store so don't worry about damaging it. This could be an issue also. If you have never removed a stuck woodruff key, you may want to see if the machine shop will do it for you (mine was a LOT of work).
11) Slide off the plastic roller
12) Clean the shaft with fine sand paper or steel wool
13) Put everything back together and slide the motor back in. Note: getting the plate (part 23) aligned with the frame took a good bit of effort on mine.
14) Oh, and make sure you lube it up (I use dry silicone spray).
15) INSPECT the rail teeth for stuck pieces of the broken gear (I had a few)
16) Resync'ing the motors? Mine went in square with no issues once back together so I did not have to do anything. I did go in/out/in/out/in/out (3 times) an inch or so quickly (as I read that syncs the motors) before bringing it all the way in. That may have simply been voodoo, but I since a stream of obscenities was what released the inner step bearing, I figured voodoo wouldn't hurt.