I was attempting to dismantle the gears, but came across a tiny bolt whose head was broken off. This particular bolt, when tightened, holds the largest blower gear to its shaft (axle). I can go no further till I figure out how the xxxx to loosen this tiny bolt. Any help would be greatly appreciated. I don't believe it's possible to use a "screw extractor" because of the close confines. Also, drilling out the broken bolt is not feasible for that same reason. I'm enclosing several pictures.

stainless rod and build it up til you can get a hold of it. is it drilled on an angle? almost looks like ot would have to be to drilled and tapped in the first place. if so a long drill bit maybe? dunno maybe other better ideas from someone with better experience

stainless rod and build it up til you can get a hold of it. is it drilled on an angle? almost looks like ot would have to be to drilled and tapped in the first place. if so a long drill bit maybe? dunno maybe other better ideas from someone with better experience

I can't tell for sure, but it appears not to be angled at all. How the drilling and tapping was done in such a small, tight space is beyond me. I have a welder friend, I'll see if he can do as you suggested. Thanks for the info.

I rebuilt a Buffalo blower that looks identical to yours. The large gear on mine was not held in place by a screw. It had a taper pin that secured the gear to the shaft. I suspect yours is the same.

Just pulled mine apart, and was also a taper pin... use a pin drift to knock it out.

Since blowers tend to "wear into" their gears. Taking them all apart can result in a blower that runs *worse* afterwards than before. Did you mark each gear as to it's exact mesh?

Tom what brands have you found this issue? I have done a rebuild/service on about 5 buffalo and 3 champions with the end result always better than the start, granted this is only a small number.

I don't recall as that was about 25 years ago. I just remember that they ran a bit noisier after the clean up than before.