Sooo... what do you guys do on the one's that are so damned rusted that it just won't willing to come out ? (typically, totally rusted up)
Mostly condenser fan in residential unit and some blower fan on packaged commercial units. Often times, after trying for 20 minutes, I give up and just grab matching (or at least similar one) from supplier. The only thing I don't like when this happens is... it's PITA to try to get exact same pitch/diameter, etc from the supplier and OEM parts tend to be.... 4 days away when customer is yelling... "NOW".
Posi locks are worth the money if you have to pull a lot of fans. We had a few Trane RTAC chillers that went through a cracking fan blade spell. The fan blades were rust welded and ate supply house fan pullers like candy. Picked up a posi lock and coupled it to a 1/2" impact and never looked back. Also as a side note: when installing the new blades I coated the inside of the hub and motor shaft with marine grade antiseize. Once installed I painted the top of the fan hub and shaft with antiseize (a thin coat doesn't sling and holds up to elements). Whenever we change motors or blades now honestly we just loosen set screws and pull by hand or a slight deadblow tap.