Last christmas my polar express smoke plunger kept sticking, freezing up. Result no smoke. I change the spring that didn't help. So my question is, what parts should I buy to fix the issue. Thanks for any help or input.
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Well, first clean all the residue out of the cylinder and piston and see if that helps, use something like naphtha (lighter fluid). Sometimes the plastic barrel gets deformed, then you will need to buy a new smoke unit.
Thanks GunRunnerJohn. Yes, I tried cleaning, but it still freezes. After i take it apart and put back together, I would get a minute or 2, then freezes up again. Seem like the plunger goes on a slight angle (jams) and won't push back down. Was thinking maybe just the plunger itself. I guess a whole unit will solve the problem, however a few days ago I was looking at parts, I didn't the whole smoke unit for sale. Well if lionels web site ever comes back up, I'll look again thanks.
You could try the plunger, but given the $10 shipping charge, I'd want the whole thing to make sure. 
Seems like the current starter sets the smoke lever is positioned at such an angle that it pushes the Piston up cocked.
Carefully bending the lever slightly usually takes care of it.
Overfilling / leakage gums up the piston causing it to stick also. But sounds like you've addressed that.
If this is the type that has the tiny ball bearing on the plunger make sure it is not clogged.
romiller49 posted:If this is the type that has the tiny ball bearing on the plunger make sure it is not clogged.
No ball bearing on it.
