Industrial Gearbox Rebuild Servicesin Northwest Indiana
Quick overview
A gearbox rebuild is a full teardown and inspection of an industrial gearbox or speed reducer, with worn gears, bearings, shafts and seals replaced or machined new, then reassembled and tested. SSI rebuilds gearboxes in our Portage, Indiana shop and installs and laser aligns them on site.
What does a gearbox rebuild include?
| Component | What we do | What you get |
|---|---|---|
| Gears and pinions | Inspect tooth contact, pitting and wear. Replace or source matched sets. | Quiet running and correct load sharing |
| Bearings | Replace bearings and set preload or end float to spec | Cooler running and longer bearing life |
| Shafts and fits | Measure journals and seats. Repair or machine new shafts in our shop. | Correct fits that hold under load |
| Seals and breathers | Replace seals, check breathers and correct leak paths | Oil stays in, dirt and water stay out |
| Housings | Inspect for cracks and bore wear. Repair bores and mating faces. | A sound housing that keeps gears in line |
- Shafts made hereOur machine shop makes shafts and sleeves.
- Aligned on installLaser aligned to motor and driven unit.
- Written scopeYou see the findings before we rebuild.
How does a gearbox rebuild work?
Step 1: Receive and record
Log the nameplate, oil condition and the symptom you reported.
Step 2: Tear down
Disassemble, clean and tag every part.
Step 3: Inspect and measure
Check gear contact, bearings, shaft fits and housing bores. Send you a written scope.
Step 4: Rebuild
Replace or machine worn parts. Set backlash, contact and bearing settings to spec.
Step 5: Install and align
Set the gearbox and laser align it to the motor and driven equipment.
Step 6: Test and report
Run it, check noise, heat and leaks, and hand you the records.
Signs of gearbox trouble
When does a gearbox need a rebuild?
Most gearbox failures give warning. Call when you notice these.
- Growling, whining or knocking
- Housing or oil running hot
- Oil leaks at seals or joints
- Metal particles in the oil or on the drain plug
- Rising vibration readings
- Repeat bearing or seal failures
What is a gearbox rebuild?
A gearbox rebuild returns an industrial gearbox or speed reducer to manufacturer spec by tearing it down, inspecting every part, replacing or machining what is worn, and reassembling it with correct settings. SSI rebuilds gearboxes in our Portage, Indiana shop, then installs and laser aligns them in your plant.
Gearboxes run conveyors, mills, mixers, fans, presses and pumps. When one fails, the line stops. A rebuild done right puts that unit back in service for the long haul, usually for less than a new gearbox and without new foundations or piping changes.
What do we check when we open a gearbox?
When we open a gearbox, we check the gears, bearings, shafts, seals and housing, and we look for the reason it failed. The failure mode tells us more than the broken part does. Pitting, scoring or uneven contact on gear teeth points to load, lube or alignment problems we fix during the rebuild.
| Area | What we look for | Common cause |
|---|---|---|
| Gear teeth | Pitting, scoring, wear pattern, cracks | Overload, poor lubrication, misalignment |
| Bearings | Spalling, heat discoloration, looseness | Contamination, wrong preload, misalignment |
| Shafts | Journal wear, fretting, bends, keyway damage | Loose fits, shock loads |
| Seals | Leaks, hardening, worn sleeves | Heat, age, shaft wear |
| Housing | Cracks, worn bores, distorted faces | Soft foot, base problems, shock loads |
| Oil | Metal, water, sludge, wrong grade | Wear, seal failure, missed changes |
How does our machine shop speed up a gearbox rebuild?
Our in-house machine shop makes shafts, sleeves, bushings, keys and spacers instead of waiting on outside vendors. When a part is obsolete or on a long lead time, we measure the original and machine a new one to fit your gearbox. That keeps the rebuild schedule in our hands.
For gear sets, we source OEM or quality aftermarket parts and tell you the lead time up front. If a gearbox is critical and has no spare, ask us about planning the next rebuild before this one fails.
Rebuild or replace your gearbox?
Rebuild when the housing is sound and the wear is in parts that can be replaced. Replace when the housing is cracked, the ratio no longer suits the process, or parts can’t be sourced sensibly. We show you what we find and give you a straight answer, not the most expensive one.
- Rebuild usually wins on large or custom units, older units with sound housings, and drives where a new unit means base or piping changes.
- Replacement may win on small standard reducers, or when the housing is damaged beyond repair.
For more detail, read gearbox rebuild vs. replacement.
Why does alignment matter after a gearbox rebuild?
A rebuilt gearbox set on a bad base or out of line with its motor will fail the same way the old one did. Our crews check soft foot and the base, then laser align the gearbox to the motor and driven unit. You get before-and-after readings for your files.
Gearbox rebuilds are part of our broader equipment rebuild work. We do them for steel, pulp and paper, refractory and power plants across Northwest Indiana and Chicagoland. If a gearbox is down now, call (219) 386-1506, day or night.
Gearbox Rebuilds across the Region
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Gearbox Rebuilds FAQs
What does a gearbox rebuild include?
A gearbox rebuild includes teardown, cleaning and inspection of every part, then replacement or machining of worn gears, bearings, shafts and seals. We restore housing fits, reassemble with correct backlash, tooth contact and bearing settings, and test the unit. When it goes back in, we laser align it to the motor and driven equipment.
How long does a gearbox rebuild take?
It depends on the size of the gearbox and what parts it needs. Many rebuilds take 1 to 2 weeks. Gear sets with long lead times are the usual holdup. When we can machine shafts, sleeves or bushings in our own shop, that part of the job does not wait on anyone else.
Is it better to rebuild or replace a gearbox?
Rebuild when the housing is sound and the wear is in gears, bearings, shafts and seals. Replace when the housing is cracked, the ratio no longer suits the process, or gearing cannot be sourced at a sensible cost. We inspect it, show you the findings and give you a straight recommendation.
What are the warning signs of gearbox failure?
Common signs are new noise like whining, growling or knocking, a housing or oil that runs hot, oil leaks, metal particles in the oil, and rising vibration. Repeat bearing or seal failures often point to misalignment or a worn fit. Catching these early usually means a smaller rebuild.
What types of gearboxes do you rebuild?
We rebuild industrial gearboxes and speed reducers, including parallel shaft, right-angle and shaft-mounted units, plus gear drives on conveyors, mills, mixers and presses. We work on many makes and models and source OEM or quality aftermarket parts. Our shop machines parts that are no longer available.
Can you make gearbox parts that are no longer available?
Yes, for many parts. Our machine shop reverse-engineers and makes shafts, sleeves, bushings, keys, spacers and covers from the worn originals. For gear sets, we source from OEM or qualified suppliers. We tell you up front which parts we will make and which we will buy.
Why do gearboxes fail after they are rebuilt?
The most common reasons are misalignment, soft foot, the wrong oil or oil level, and contamination. That is why we check the base and laser align every rebuilt gearbox on install. A rebuilt unit set on a bad base will fail the same way the old one did.
Do you pick up gearboxes for rebuild?
Yes. Our crews can pull the gearbox, rig it out and bring it to our Portage shop, then reinstall and align it when the rebuild is done. We serve plants across Northwest Indiana and Chicagoland, including Joliet, Kankakee and the Plymouth, Indiana area.
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