Nuclear Reactor Repaired

Thanks for posting.  I have a reactor that may need the same repair.  The issues you outlined are the same as mine.  

That gear looks close in dimensions to the one in the intermodal crane. Which I was able to replace with a brass gear. Not sure if it is but looks close

I’m glad that you found a solution. Most nuclear reactors I’ve come across have a “no user serviceable parts “ warning sticker.  
I guess if you know what you’re doing go for it.  I think that that would void the warranty on most nuclear reactors. 
Alan

The warranty on the reactors are long gone. It has been years since they were made.  Checking Lionel's online parts, a lot of parts are no longer available. The gear boxes are one of the parts no longer available. Repair is the only option. 

I found the repair required a moderate level of skills. You have to take a lot of screws out to remove the gearbox and disconnect wires. As long as you have good basic skills in taking things apart, users can fix it.  Now, to put the gear on, I used my vice as a press. I had a nice hard plastic tube the right size to fit over the shaft but smaller than the gear to allow me to press the gear on. That has to be done right so you dont bend the shaft. Once done, I had mine back together in less than 1/2 hour.

Learn something new every day.  That would make sense about the nylon gears.  Once NWSL gets back on their feet, I may just order a spare delrin gear from them so I don't have to keep opening the gearbox up.  With a 2 mm bore and only a 6 mm face size, its a very small gear.  That does not leave a lot of material to handle the stress of being press fit on the axle, coupled with what you stated above.

I would just like to concur with what my fellow "nuclear tech" @KD has stated. I ordered the NWSL gear upon his recommend as well as a belt replacement from another dealer.

The repair was a beast, and I consider myself above average in mechanical skills. In a reactor teardown of this magnitude, go with the best parts you can obtain. You don't want to have to go back in there!😵

John

Joe,

Thanks for posting. My 86-year-old walking Lionel Service Station--my dad--has been working and tinkering on this piece for the last several months. We picked up ours about 10 years ago a TCA York Meet. Your advice about the connecting rod to the pellet door might have just helped us complete this repair lengthy project.

We were able to find replacement gears on eBay but just buying bags of assorted gears for RC models.

John