remove shell from Lionel shay #18023

I had same trouble with the same loco. I sent it back to Lionel and they fixed it and then ran it on their display layout in Michigan.  They sent me a letter telling me about it running on their layout. A couple months later it stopped running again. This time I took it apart and found all the power wires, maybe 6 or 8, all are connected by one single wire nut. Some of the wires are very small, and a wire nut just does not work in this application. Solder and heat shrink took care of the problem, but makes future repairs more difficult.  It would be a good opportunity to add a TVS inside the loco. As to your original question, I do not recall which screws I removed. There are some screws sealed with inspectors lacquer.  Stay away from them. As I recall the parts list, which is on the Lionel web site, was a help in taking it apart. 

Doug,

I have removed the shell on several Shays. It is a very tight fit!!!! Harder still is getting the shell back on correctly without pinching or folding wires. It takes some time and a lot of patience. One thing that helped (and it may help with removing the shell) is to loosen the sides gears first. There are two screws right below the side gears on the bottom of the locomotive that loosen it. I DID NOT remove the gears completely, so be careful not to back the screws out too far. I am not sure if this really did help, but I was able to replace the shell after doing so. As I said, the shell fits very tightly but can be removed with GENTLE pressure on it.

Just be ready for a tense struggle, because I did not find it to be an easy task working on them. Perhaps you will

Good luck,

dennis

Its been a while since I took one apart but believe Dennis has hit on it. The cylinder block may be holding it in place. Check for screws above and behind the cylinder block. Note how the cylinder block fits as you have to align it on the boiler as you slide it back on.

Pete

Thanks to everyone who replied.  I finally got the shell off.  There are four screws on the bottom that hold the boiler on.  With the screws out I was able to pull the frame up enough in the front of the engine to pry it gently out.  Actually came out pretty easy. 

The big bunch of wires under one wirenut sure looks like a potential problem.

I need to replace the rear coupler on a shay I just purchased, and found this thread with the search function.  I see 8 screws on the bottom, 2 on each end look to hold the steps on, and then there are 2 more to the rear and 2 a little forward of the engine's center.  I'm guessing it's the two on the end and in the middle that will allow the shell to come off?

Thanks for the help!