My drive gear has worn on my model 139.53962SRT1 garage door opener. I ordered PN 41A2817 Drive/worm gear kit to replace the drive gear. Do I need to remove the chain in order to replace it? Also, any suggestions regarding the process of replacing the drive gear?
Using the 41A2817 kit, you should be able to change the gear without removing the chain. Just be sure to synchronize the door position with the limit switch position when you are done as both of them take their drive off the same gear assembly.
If you start with the door all the way up and the limit switch in the up position and then install your parts you will have a good reference point to get the two back in sync afterward but remember that you still may need to fine tune the upper and lower limits slightly when you are finished.
Once you are finished you will also need to test your safety systems to be sure the door is stopping and reversing as it should. I have included some links below with more information on testing the systems and other tips that might be useful during your repair. There is also important information in your owners manual that you might want to review and if you have any remaining concerns or doubts you may want to consult a professional to be sure there is no risk of the door jamming or hurting someone.
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