Okay got my photos working.

Here I'm removing the 2 bolts holding the pump and motor together:





Here is the order of assembly. On the bottom is the pump case, then the motor case with the magnets inside, then the outer motor cover with the coil and shaft installed:




Here were looking at the bearing failure. This is the bearing installed at The end of the shaft towards the pump.





This is the hole where the bearing slides in and supports the D shaft. The crap your seeing is old grease, ground down metal, dirt and god knows what else.






there is a spring washer inside the bearing hole to keep tension on the bearing.




Here is a cleaner view of where the bearing installs. You can see a red seal in there that seals the liquid side of the pump from the electric side of the motor.





What I don't understand Is that the seal looks to be fully functional. If it wasn't, there would be fuel getting I to the coil and contact side of the motor causing it to short out.
There is also a large diameter o ring on the outside of the motor housing where it meets the lump housing keeping dirt from getting into the motor.


Now that I have the NEW motor I stalled and know how quiet these are SUPPOSED to be, I'm thinking this bearing was destined to fail from day 1.


The bearing has a lot of play in it telling be that it was eaten from the inside out. I had originally thought maybe the fuel filter was not changed often enough causing this buildup, but where this bearing is located behind the seal, this is not the case at all.


I think I might send these photos and explanation , to air dog and see what they think..

 

The newer AD's are extremely quiet....not sure of the differences between the new/old versions. Mine is of the older version but has served it's purpose well. About 3 weeks ago it failed on me. I had noticed (a little) that the pump was getting progressively louder than usual. When it went out I called AD and told them what had happened and all the things I had tried as far as troubleshooting....they didn't have a clue what was causing my issue. They did however ask me to remove the motor housing cover and take a look at the brushes to see if they were worn out. What I saw when I removed the cover was a little disturbing. FUEL ran out of the motor housing and it was full of sludge.

As requested I sent the pump into them for repair. They said the whole pump had to be sent in because the motor has to be calibrated with the pump ...I didn't understand this but oh well. The same day they received the pump it was ready to be shipped back out . Turns out, almost like your case, that my pump seals had failed and let fuel into the motor housing causing it to short out and keep blowing it's 20A inline fuse.

AD was great about holding up their end of the warranty bargain. They installed new pump seals and a NEW motor and all I was out was shipping charges. Because mine is of the older version it is still way louder than the AD2 but much quieter than before it went out on me.

 

Mine did the exact same thing. The Airdog 1 didn't have a lifetime warranty, the replacement they sent you will have a lifetime warranty. The motor is of a different design.

 

I think I have the exact same motor as the old one since they both have the exact same model number stamped on the housing.
Then again, this motor is 300% quieter so maybe they redisigned the guts.

 

Well that sounds like some good news. I'm all about a lifetime warranty.