update - I don't know how but every thing is OK? I pounded the gear and key back into the key way slot, cut off as much key as I could, took a welding stick, grounded it down to fit in the other end of the key way, taped with a hammer / got another 1/4" key exposed, cut it off, taped the rod a little more, cut off some more exposed key, taped a little more, the rest of the key fell out, gear came off, took assembly out of the unit.
update - guess what? The machine sounds just about the same, a little less but not worth $130 in bearings.