Replace this gear

It’s doable with a small punch, a vise, or a block of hard wood, & couple dimes. I’ll do my best to explain the procedure,…..

1. on the gear train side, scotch tape a dime to each wheel ( this will prevent the axles from accidentally being driven out during the process )

2. position the truck on its side, resting on the dimes.  

3. with a punch slighty smaller than the gear shaft, tap on the shaft to drive it out of the shaft retainer, being very careful not to strike the shaft retainer. Save the retainer for reinstallation. Finish tapping the shaft off the broken gear. Clean all parts, check for any burrs.

4. check fitment of new gear. If overly tight, it may crack again. It may have to be bored for a better fit.

5. fashion a shim 1/32” thickness and set aside . This will be used to keep the new gear centered in the gear box bore. A small washer cut in half works great for this.

6. swap your dimes to the other side for installation. Begin by inserting the shaft into its bore, and catch the new gear. Do a couple taps, and verify your new gear is driving on straight. The spur gear will not yet have engaged the others, so you can spin it to see it’s true. Tip: do not strike the spur gear with the punch!!…

7. drive shaft into gear with punch & hammer until you just get into the splines on the gear shaft. NOW insert your 1/32” shim between the new gear, and the gear well on the bottom side, and continue to drive the shaft until the large spur gear mates  to the idler gears. Tip: as you drive down, watch spur gear alignment!…do not crash gears!

8. remove shim, and check the new gear centering. When correct, the spur gears should have good alignment, and your new worm wheel gear should be centered in the gear well.

9. Check shaft retainer for fitment. If  still tight, it can simply be driven back on leaving a 1/64” gap between the retainer and the block. If retainer is loose, use loctite green shaft & sleeve retainer to secure it. Do not let the loctite wick towards the block!  Tip: use a nut driver of suitable size to tap retainer back onto shaft. Before installing retainer, support drive block on the spur gear shaft you just installed!!…or you’ll undo, what you just did!..

10. let cool, serve & enjoy. 😉

Pat

@harmonyards posted:

It’s doable with a small punch, a vise, or a block of hard wood, & couple dimes. I’ll do my best to explain the procedure,…..

1. on the gear train side, scotch tape a dime to each wheel ( this will prevent the axles from accidentally being driven out during the process )

2. position the truck on its side, resting on the dimes.  

3. with a punch slighty smaller than the gear shaft, tap on the shaft to drive it out of the shaft retainer, being very careful not to strike the shaft retainer. Save the retainer for reinstallation. Finish tapping the shaft off the broken gear. Clean all parts, check for any burrs.

4. check fitment of new gear. If overly tight, it may crack again. It may have to be bored for a better fit.

5. fashion a shim 1/32” thickness and set aside . This will be used to keep the new gear centered in the gear box bore. A small washer cut in half works great for this.

6. swap your dimes to the other side for installation. Begin by inserting the shaft into its bore, and catch the new gear. Do a couple taps, and verify your new gear is driving on straight. The spur gear will not yet have engaged the others, so you can spin it to see it’s true. Tip: do not strike the spur gear with the punch!!…

7. drive shaft into gear with punch & hammer until you just get into the splines on the gear shaft. NOW insert your 1/32” shim between the new gear, and the gear well on the bottom side, and continue to drive the shaft until the large spur gear mates  to the idler gears. Tip: as you drive down, watch spur gear alignment!…do not crash gears!

8. remove shim, and check the new gear centering. When correct, the spur gears should have good alignment, and your new worm wheel gear should be centered in the gear well.

9. Check shaft retainer for fitment. If  still tight, it can simply be driven back on leaving a 1/64” gap between the retainer and the block. If retainer is loose, use loctite green shaft & sleeve retainer to secure it. Do not let the loctite wick towards the block!  Tip: use a nut driver of suitable size to tap retainer back onto shaft. Before installing retainer, support drive block on the spur gear shaft you just installed!!…or you’ll undo, what you just did!..

10. let cool, serve & enjoy. 😉

Pat

Thanks for the instructions.  Now to find the correct gear.