Do you have a broken gearbox that needs to be repaired or replaced? Gearboxes can be very costly to replace, especially if their disrepair has forced production to an unexpected halt.
Replacing a gearbox from an OEM can take months, and that’s assuming they are still in business and making the type of unit you need.
In most cases, gearbox replacement is unnecessary. Professional gearbox repair service companies can restore your gearbox with optimal performance, often at less cost and significantly faster than an OEM replacement.
Benefits of Gearbox Repairs
The two main benefits of gearbox repairs are cost and turnaround time. Gearbox repairs can cost significantly less than a new OEM unit.
Additionally, high-quality gearbox repair shops can provide superior performance for gearboxes over standard OEM parts. Increased speed, higher tolerances, and greater precision can be achieved through attention to detail and quality workmanship.
In terms of turnaround time, some repairs can be completed within 24 hours, which is a huge time advantage compared to ordering a new gearbox replacement. There are times when repairs are impractical, but in most cases, gearbox repair is the better option.
6 Steps to Repair a Gearbox
Gearboxes are sophisticated machinery that need both strength and precision when being repaired. The right gearbox technician has years of machining experience in gearbox assembly and repair under their belt. They can evaluate the status of a gearbox and how well repairs will hold up.
Here are the six basic steps to repairing a gearbox:
1. Initial Assessment
Contact a qualified gearbox repair shop and ask for an initial repair assessment. A few pictures and some explanation should be enough for an experienced repair shop to determine if they can accomplish the job. Additionally, it should be enough for them to give a basic estimate of how much it will cost and how long it will take to repair the gearbox.
2. Thorough Assessment
Once the repair shop has received the gearbox, a full component inspection begins. An outer and inner visual inspection is performed, along with checking the overall functionality, bearing settings, and backlash. Any wear and tear, hairline cracks, and other issues are noted.
3. Disassembly of the Gearbox
The gearbox is fully disassembled, and all the components—including the bearings—are removed and laid out. The condition of each component is captured and recorded.
4. Condition Report & Failure Analysis
After the initial assessment and disassembly of the gearbox, the technician reports the condition of the internal components, which will include photographs of your drive and any noticeable damage. The main reason for gearbox failure and faulty parts are identified, along with any other damage. You will be given an updated quote that details all the required work involved and any recommendations for part replacement.
5. Rebuilding the Gearbox
Once the new quote has been approved, the real work can begin. Here is some of what goes into rebuilding the gearbox:
- Cleaning exterior and interior components
- Removing all screws, bolts, and connections
- Disassembling all components
- Inspecting all parts, especially the gears, shafts, and pinions
- Replacing all worn-out parts
- Rebuilding or custom-making components to OEM specifications
- Replacing all bearings and seals
- Aligning all components
Broken or damaged parts are replaced, even if it means some components or gears have to be custom-made. Undamaged parts are cleaned and reused rather than replaced, which saves time and money.
Components that often need to be replaced are gears, pinions, and shafts. Seals, shims, and bearings are almost always replaced with tier 1 vendor parts.
Finally, the entire gearbox is fully reassembled and prepared for testing.
6. Gearbox Testing & Quality Assurance
After all the pieces of the gearbox have been cleaned, replaced, or remade, all the parts are reassembled. Gear clearances are tested, and a no-load spin test is conducted.
Vibration and noise tests are conducted, and all pieces are proven to work together. If all the initial tests are passed, parts are then sandblasted. Any parts and exterior pieces can be painted upon request.
It’s best to find a gearbox repair shop that is all-inclusive. This means that they are able to perform various services, including custom gear fabrication, magnetic particle inspection, presswork, and more.
Lawler Gear’s Expert Gearbox Rebuilding Services
Lawler Gear is a full-service gearbox repair shop that specializes in rebuilding and replacing components on gearboxes. Our gearbox technicians have years of experience in shaping, inspecting, broaching, turning, milling, grinding, and gearbox rebuilding. We can make custom gears for any application.
We replace gears, shafts, bearings, and seals. In most cases, we can rebuild gearboxes for less than the cost of a new once.
Lawler Gear has experience working with gears from a wide range of industries, including agriculture, construction, mining, food processing, large machinery, material handling equipment, and more!
We provide the following gearbox-rebuilding services:
- Component inspection and troubleshooting
- Teardown and rebuilds
- Shaft accessory replacement
- Presswork (to 100 tons)
- Shaft and gear work
