Question about KitchenAid 3-Speed Blender Onyx Black KSB540

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How to remove a stuck coupler - KitchenAid 3-Speed Blender Onyx Black KSB540

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Stick a flat blade screwdriver underneath it and lever it off from a couple of sides. The threads will pull out of the coupling as they are weak aluminium. Pick the bits of thread out of the top of the motor shaft before fitting the new one. This is the Kitchen Aid recommended method not my dodgy cunning home made plan.

Posted on Jul 26, 2014

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Posted on Jan 02, 2017

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My coupler was split in two, and I couldn't screw it off. I had to do the following:
1. Take the blender apart (mine had 2 screws on the bottom). 2. Remove the motor housing from the blender (mine was loose from removing the two screws earlier). 3. Remove the fan by removing the fan nut. 4. Take apart the motor housing. Mine had two machine screws with 1/4" hex heads holding a bracket that tied the two ends together. Once those two screws are removed, you can take the motor out of the housing. Be careful on the fan end of the motor, because it's got two spring loaded brushes that will come together once the motor is pulled through. 6. Once you have the motor out of the housing, you'll have something to grab onto so you'll be able to unscrew the broken coupler. I used a pair of channel locks and gently grasped the motor body, and then just used a regular pair of pliers to grab the broken coupler. It's regular thread (lefty lucy righty tighty), so twist accordingly.
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When I took it to my authorized KitchenAid repair guy he said you need a 7mm wrench and you need to make sure it has a VERY thin depth/girth of the wrench. He actually held his wrench tip to a metal sander and made it thinner on each side without compromising the integrity of the torque of the wrench. This is to make it fit properly under the coupler and around the shaft. Anyway, can rip off the rubber cap of the coupler, hold the metal disc part TIGHT with pliers, and stick the wrench beelow the coupler and above the base body. (The rubber coupler left still on it might make it easy for the pliers to grab, but you rish tearing it and maybe stripping the shaft or your wrench. Make sure the rubber piece is good and strong if you are going to do this.) If you look hard at the rotator shaft sticking up, it is not completely round -- it has two flat sides (for the wrench to brace it). Lastly, to finally loosen the coupler off the shaft, you hold the wrench constant on the shaft and you twist the pliers CLOCKWISE, as though you would be tightening something. Again, LOOSEN=CLOCKWISE. You are not tightening... The coupler thread is opposite the normal threads we are used to. The coupler is lefty-tighty and righty-loosy. The trick, I believe is finding the perfect wrench so that you don't feel like you are stripping the shaft or wrench. Then you get your new coupler and lefty-tighty it on.

Aside: Looking at the coupler, after the rubber is pried off, you can imagine that there is a special tool that fits into the little holes to make the twisting easier. My repair guy thinks this was the original intent, but perhaps the special tools for this repair process are not available since now there is an newer KitchenAid blender out with a different coupler design (and repair process). But this works. I even bought an extra coupler off him to do it myself the next time. The "authorized" dealers are few and far between in my part of the country, my nearest 3 hours away. I couln't even find a closer "unauthorized" person to repair it! I loved this blender enough for the 3 hour trek, though.

Hope this helps!!

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