Lionel ZW gear jumping fix

How can we get this replacement part?  Is the 3D printer file available?

Thanks!

Mitch

jimmysb, great video especially in light of the difficulty finding a service center that will take in a ZWC. I now have confidence in synching the potentiometers with the handles. in addition to my ZWC jumping gears, the (right side) accessory and track handles have an 1/8 to 3/16" gap between each other and the transformer casing thus causing the handles to have play as well as slide in and out horizontally. so I ask in addition to remedying the play with the install of a new bracket, is there a way to tighten the handles on the shaft , essentially drawing each closer together and to the transformer casing  to eliminate the horizontal play? I am thinking that this horizontal play may be contributing to the gear jumping in my case. I have (2) ZWC's and this condition only applies to the right side handles on one of them. any additional light you can provide would be awesome. Thanks

@CMac my transformer did not have horizontal play but it was very loose up and down.  That's what the little c clamp bearing under the metal plate fixed.  I think the gears are pressed on so you might try that, but not sure. The pot bracket that I made more beefy also had to have the holes for the pots somewhat lower to take away any play between the gears.  I have a metal bracket in my ZWC too.  That is one change I know Lionel did that you will need to make my hack work.

@M. Mitchell Marmel posted:

How can we get this replacement part?  Is the 3D printer file available?

Thanks!

Mitch

I have my website which I can either put a part or digital file on.  I haven't got the woocommerce store up yet.  The store is a way to get free or purchased items.  My goal with my website is to create cool train items that I can make and maybe others would like as well as videos of fixing and running postwar trains.  Fixing my ZW was so rewarding since its was not very usable in its jumping gear state when I got it 10 years ago.  I also plan to make whimsical contraptions too.

jimmysb, thank you for following up.  I believe as you say that the handles are pressed on and perhaps I can get some leverage to compress them when  removing the bracket to synch the pots. Thanks, all the best

I have the same problems. Would you be interested in making more brackets and selling them for those of us who don't have a 3D printer (& the knowledge to use it) Also, can you post pictures of the bearing before you installed it? Does it go around the shaft or just press down. Thanks for sharing this fix

I am behind on getting the website store up for free or purchased items.  It will be at www.jimmytrains.com

The website is now up with the lionel zw bracket and bearing. https://www.jimmytrains.com/pr...et-and-axle-bearing/

Worked Great -

@shawn  I am glad to hear that it worked for you.  Did you replace just the right handle?  Did you also use the axle bearing?

Both Sides- Why bother doing one. I've repaired about 10 of these using cnc metal brackets. But, no longer have access to the equipment. Yes, I did use the palastic bearings.  Although, I found the sanding leaves sand paper granules behind scoring the post - no big issue - Heavy cleaning  after sanding. The pot bracket is perfect. 

@shawn  I am confused about the sanding.  Did you sand the bearing outside the transformer.  Only the flat area needs sanding and then clean up with soap and water or alcohol.

I finally found a small enough allen wrench. I removed 1 gear assy. However, I am unable to remove the 2nd allen bolt. any ideas on how to do it? is there a thread locker?