STAGE 1/7
Each case below is a complete repair file: what the customer reported, what the teardown found, the machining and parts work performed, the test-stand numbers at sign-off, and the cost against the OEM replacement quote. The interactive version above lets you split the housing, inspect the damage in 3D and configure your own estimate. Everything on this page is also readable as plain text.
Across these five repairs the work averaged 76% below the cost of a new unit and shipped in an average of 10 business days, against the 16 to 30 week lead times typically quoted for new industrial gearboxes. Total repair value: $56,400 against $237,200 in replacement quotes.
| Customer | Unit | Repair | New unit | Saved | Shipped |
|---|---|---|---|---|---|
| Apex Cement Houston, TX | Falk 2090Y3 250 HP · Cement ball-mill drive | $18,400 | $98,500 | 81% | 12 days |
| Gulf Coast Refining Port Arthur, TX | SEW-Eurodrive R97 75 HP · Cooling tower fan drive | $6,800 | $24,900 | 73% | 9 days |
| Midwest Steel Gary, IN | Dodge TA6307 150 HP · Slab-yard conveyor drive | $11,200 | $41,800 | 73% | 10 days |
| Pacific Aggregate Fresno, CA | NORD SK 9012.1 200 HP · Cone crusher feed drive | $14,600 | $52,300 | 72% | 11 days |
| Bayou Chemical Baton Rouge, LA | Sumitomo Cyclo 6000 40 HP · Reactor agitator drive | $5,400 | $19,700 | 73% | 8 days |
Falk 2090Y3 · 250 HP · Cement ball-mill drive
Three fractured teeth on the intermediate helical wheel, cement dust in the sump, and a spalled output bearing.
Repaired for $18,400 against a $98,500 replacement quote — 81% saved, shipped in 12 business days.
SEW-Eurodrive R97 · 75 HP · Cooling tower fan drive
Worm wheel bronze wiped from chronic overheating, plus water ingress through a failed shaft seal.
Repaired for $6,800 against a $24,900 replacement quote — 73% saved, shipped in 9 business days.
Dodge TA6307 · 150 HP · Slab-yard conveyor drive
Broken tooth from shock loading on a jammed conveyor, with secondary bearing damage from the debris.
Repaired for $11,200 against a $41,800 replacement quote — 73% saved, shipped in 10 business days.
NORD SK 9012.1 · 200 HP · Cone crusher feed drive
Abrasive wear across every contact surface from rock dust ingress, and a cracked housing at the input flange.
Repaired for $14,600 against a $52,300 replacement quote — 72% saved, shipped in 11 business days.
Sumitomo Cyclo 6000 · 40 HP · Reactor agitator drive
Cycloidal disc and eccentric bearing wear after 14 years without a rebuild, plus scored pin housings.
Repaired for $5,400 against a $19,700 replacement quote — 73% saved, shipped in 8 business days.
Every case in the interactive walkthrough follows the same seven stages, because every gearbox that comes through the shop follows them:
Across the five documented cases on this page the repair ran between 27% and 35% of the new-unit price. The Falk 2090Y3 cement mill drive was repaired for $18,400 against a $98,500 replacement quote — an 81% saving. As a working rule, a full rebuild lands at 30-60% of new, and the gap widens on older or obsolete units because a replacement often means re-engineering the mounting and coupling as well.
The cases here shipped in 8 to 12 business days dock to dock. That compares with 16 to 30 weeks of lead time typically quoted for a new industrial gearbox. Emergency line-down work can be compressed to 24-72 hours when the unit is on our dock and the tooth data is already known.
Yes. A fractured tooth is one of the most routinely repaired failures. The replacement gear is cut from 8620 alloy steel, carburized and ground to match the surviving geometry — in the Apex Cement case, a 27-tooth 8DP 15-degree right-hand helix wheel was reverse-engineered from the teeth that survived, so no OEM drawing was needed.
Obsolescence is not a barrier. Tooth geometry is measured directly off the surviving parts — pitch, pressure angle, helix angle, face width and backlash — so the part itself becomes the drawing. Several units on this page are from lines that have been out of production for decades.
The unit is received and photographed as-found, the housing is split, every component is tagged and racked in teardown order, and the oil is sampled and sent for particle-count analysis. What that inspection finds becomes the written quote. There is no charge for the teardown and inspection.
Every unit runs on a load test stand. The five cases here were signed off on gear mesh backlash, vibration in inches per second RMS, oil temperature rise over a four-hour run, contact pattern across the face width, and verified ratio. Test-stand numbers ship with the gearbox.
Yes. The documented cases cover Falk, SEW-Eurodrive, Dodge, NORD and Sumitomo. Repairs are also routine on Flender, Lufkin, David Brown, Winsmith, Philadelphia Gear, Rexnord, Cone Drive, Boston Gear and Bonfiglioli, among others.
Send the nameplate photo and a description of the symptoms and you will have a written quote, not a range. Teardown and inspection are free. Call (641) 519-6270 or email surplus713@gmail.com.
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