Lionel SD40-2 Issue

Is that a steel frame or diecast?  If it's steel, it can probably be bent back fairly easily.  If the bent part is diecast, I wouldn't try.

It looks like the whole front of the chassis is bent, that's likely steel.  It'll probably have to come apart to fix it, I wouldn't try bending it with it all together.

Lionel needs to fix the packaging of these SD40's. Every one I have received has had an issue with either the front or rear coupler/deck. 

this is interesting - i had a problem with a new SD40 that had the front coupler loose in the box and the body had a nice crack in it - i guess the box was "dropped" but do not still understand why the coupler was off and not connected - its fixed now but the front grill does get stuck on the track - seems to be hanging lower then it should - i took it off and reattached it seems to be working ok - BTW the front is not steel i took it off and tried to bend it up and it broke - ordered new one from Lionel and re-installed - hope it works next time

It's diecast on my SD40.

Diecast is probably going to be more difficult.  Not that it can't be done, but it's not as simple as bending steel back into shape.  It's also sometimes not successful.

Since stated above that it’s not metal save yourself the aggravation and send it back to place of purchase. 

romiller49 posted:

Since stated above that it’s not metal save yourself the aggravation and send it back to place of purchase. 

Die-cast zinc and steel are both "metal" - as are lead, brass, gold, silver, bronze, tin, mercury....

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Atlas SD40's from some years back had a bent pilot/packaging problem. At one time I owned 3 (all GM&O), but I sold 2 of them some time back. Fortunately, the Atlas issue was not as bad and I was able to push it back into shape. I sympathize.

I talked to the dealer. He does not have anymore of them. Calling Lionel tomorrow.

Thanks for all the advice.