NikGrey: I acquired a DC40 on trash pickup day last week. I know what they cost and it was free. I'm a pensioner. My motto is "If it's free, it's for me". Tested it and was obvious that the motor/fan was bad. Screamed like a jet engine. Stripped it down and just like your experience, could not the get the motor out. Googled for assistance and SAW YOUR POST. Very helpful. Removed motor/fan assembly in minutes. Now have motor assembly and internal hose on order. Joined your forum as I'm sure I'd need help putting this all back together. Thank you.