Direct
Maintenance
Services
Industrial Gear & Gearbox Repair
24/7 EMERGENCY TRIAGE • FREE NATIONWIDE PICKUP • MINIMAL DOWNTIME GUARANTEED
Gearbox failed? Line stopped? Making noise or leaking?
Every minute costs thousands. One call to D.M.S. - 24/7 emergency fleet dispatched anywhere in the USA. Free insured pickup. Live gearbox expert answers in seconds.
(832) 860-5493
Email: INFO@DIRECTMAINTENANCESERVICES.COM
Industrial Gearbox & Gear Reducer Repair
D.M.S. is the nationwide leader in industrial gearbox and gear reducer repair - from 1 HP to 10,000 HP, parallel shaft, planetary, worm, helical bevel, right-angle, extruder drives, and custom multipliers. We perform full in-house gear cutting, reverse engineering, and dynamic load testing to deliver zero-downtime overhauls that routinely outlast new OEM units by 5-10x.
Detailed 15-Step Gearbox Rebuild Process
Comprehensive Gearbox Rebuild Process
1. Free Pickup
Zero-cost insured transport
2. Inspection & NDT
Digital triage & crack detection
3. Teardown
Complete base disassembly
4. CNC Boring
Restore housing to OEM size
5. Gear Cutting
Hobbing & tooth resurfacing
6. Bearings & Seals
Heavy-duty SKF & seal install
7. Assembly
Set precise backlash gaps
8. Load Test
Full speed & torque verify
Top 18 Gearbox Failure Modes We Fix
Top 8 Gearbox Failure Modes We Fix
From dynamic bearing exhaustion to gear tooth fracture, our engineers diagnose and rectify the core cause of failure.
Bearing Failure
Symptoms: Noise, heat. Cause: Lack of lube, overload.
Tooth Pitting
Symptoms: Methodical fatigue. Cause: Shock overload.
Shaft Damage
Symptoms: Keyway runout. Cause: Torsional twist.
Overheating
Symptoms: Oil breakdown. Cause: Fluid water ingress.
Seal Leaks
Symptoms: Constant drip. Cause: Spun bearing journal.
Misalignment
Symptoms: System shimmy. Cause: Foundation shifting.
Spline Wear
Symptoms: Tooth slapping. Cause: Backlash drift.
Case Distortion
Symptoms: Misaligned mesh. Cause: Thermal warpage.
40+ Gearbox Brands We Service
20+ Gearbox Brands We Service
We rebuild and overhaul every major brand of gearbox on the market.
Cooling Tower Speed Reducers & Fan Drives
Heavy-duty right-angle and fan drive speed multipliers built for maximum downtime in harsh, humid environments.
Amarillo Right-Angle Gear Drives
Full rebuild & upgrades. Ratio changes available. Stainless shafts & bronze bushings.
Marley Cooling Tower Gearboxes
Complete overhaul. Helical & spiral bevel gears. Thrust bearing upgrades.
Custom Fan Drive Multipliers
High-speed output for large fans. Oil cooling & filtration packages. Emergency 7-day turnaround.
Sumitomo Paramax Fan Drives
Complete planetary and helical gear rebuilds. Spherical roller thrust bearing upgrades.
Gearbox Types We Rebuild
Specialized overhauls configured for all industrial powertrain architectures.
Parallel Shaft
Single / double / triple reduction. Helical & herringbone.
Planetary
Epicyclic & star systems. High torque density.
Worm Gear
Bronze wheel replacement. High ratio specialists.
Helical Bevel
Right-angle drives. High efficiency.
Extruder Drives
Single & twin screw. Thrust bearing upgrades.
Custom Multipliers
Speed increasers. Special ratios.
B2B Industry-Specific Gearbox Overhauls
Engineered rebuilding solutions configured for the specific machinery, sealing systems, and torque demands of your B2B sector.
Wastewater Treatment
Primary Equipment: Surface Aerators, Clarifiers, Decanter Centrifuges, Screw Pumps.
Gearbox Systems: Vertical pressure-seal reactor drives, high-torque parallel/twin-screw extruder reducers, and parallel shaft mixers.
Power Generation
Primary Equipment: Coal Pulverizers, Coal Mills, Cooling Tower Fans, Boiler Feed Pumps.
Gearbox Systems: Vertical pressure-seal reactor drives, high-torque parallel/twin-screw extruder reducers, and parallel shaft mixers.
Mining & Minerals
Primary Equipment: Overland Conveyors, SAG/Ball Mills, Jaw/Cone Crushers, Thickeners.
Gearbox Systems: Vertical pressure-seal reactor drives, high-torque parallel/twin-screw extruder reducers, and parallel shaft mixers.
Chemical & Petrochemical
Primary Equipment: Chemical Reactors, Agitators, Extruders, Compounders, Rotary Dryers.
Gearbox Systems: Vertical pressure-seal reactor drives, high-torque parallel/twin-screw extruder reducers, and parallel shaft mixers.
Food & Beverage
Primary Equipment: Blenders, Industrial Mixers, Cookers, Packaging & Bottling Lines.
Gearbox Systems: Vertical pressure-seal reactor drives, high-torque parallel/twin-screw extruder reducers, and parallel shaft mixers.
Pulp, Paper & Forestry
Primary Equipment: Pulp Refiners, Stock Pumps, Debarking Drums, Wood Yard Conveyors.
Gearbox Systems: Vertical pressure-seal reactor drives, high-torque parallel/twin-screw extruder reducers, and parallel shaft mixers.
In-House Gear Manufacturing
Our Stafford machine facility houses complete CNC gear cutting, hobbing, shaping, and precise profile grinding.
CNC Gear Hobbing
We cut spur, helical, bevel, and worm gears in-house to bypass OEM lead times.
Reverse Engineering
Obsolete or discontinued gearbox? We laser-scan and manufacture parts from scratch.
Housing Reclamation
Spun a bearing? We use thermal spray and CNC line-boring to restore factory housing fits.
Heat Treating
Carburizing and induction hardening to ensure gear teeth handle maximum torque loads.
Industrial Gear Repair & Manufacturing
Obsolete or customized single-gear replacements reverse-engineered and machined with extreme speed.
One broken tooth? One cracked shaft? Don't replace the entire gearbox. We manufacture and repair single gears of any type and size - faster, stronger, and cheaper than OEM. 24-72 hour emergency cutting available nationwide.
Helical & Double Helical Gears
CNC hobbing & shaping to 60" OD. Precision grinding AGMA Q12-Q15. Crowned & modified tooth profiles.
Spur & Internal Gears
External up to 60", internal up to 50". Cluster & segmented gears. Hardened & ground options.
Straight, Spiral & Zerol Bevel Gears
Gleason cutting & grinding. Up to 40" diameter. Lapped or ground tooth contact.
Worm Shafts & Bronze Worm Wheels
Multi-start worms. Phosphor bronze & aluminum bronze. Throated & envelope designs.
Spline & Serration Shafts
Involute, straight, & helical splines. Hardened & ground. Repair worn splines with oversize.
Herringbone Gears
No-thrust double helical. CNC hobbing & grinding. Up to 50" face width.
Additional Gear Repair Services
Supplementary metallurgy testing, magnetic particle NDT, and post-weld induction hardening.
Tooth Profile Regrinding
Restore pitting & wear. Improve contact pattern. Reduce noise & vibration.
Crack Repair & Welding
MPI inspection. TIG & submerged arc weld. Post-weld heat treat.
Hard Coating & Nitriding
Plasma & gas nitriding. DLC & PVD coatings. 10x wear life.
Emergency Gear Cutting
24-72 hour delivery. Night & weekend shifts. Free pickup of broken gear.
Unmatched 12-36 Month Install Warranty
Every D.M.S. gearbox rebuild includes a 12-36 month warranty from date of installation - the longest, strongest coverage in the industry.
Industrial Gearbox
Troubleshooting & FAQs
Industrial
Gearbox
Troubleshooting
&
FAQs
Answers to the most common operational, bearing tolerances, backlash alignment, and failure modes.
How do you diagnose and fix bearing failure inside heavy parallel shaft gearboxes?
Parallel shaft gearbox bearings support massive radial and axial loads. Failure is usually diagnosed via vibration spectrum analysis or finding brass/steel particulate in the oil filtration circuit. Once disassembled, we inspect the bearing journals on the shafts and the housing bores. If spun bearings have galled the housing, we perform CNC line-boring and sleeve the housing back to exact concentric specifications before installing premium matched bearings.
When is it better to reverse-engineer and cut new custom gears instead of ordering OEM replacements?
Standard OEM gear replacement lead times can range from 8 to 26 weeks, during which your line sits completely idle. If your machinery is legacy or out of production, OEM parts may be entirely unavailable. By utilizing in-house CNC gear hobbing and tooth profile grinding up to 60" OD, we can reverse-engineer, cut, heat-treat, and ground-finish a high-strength replacement gear in days rather than months.
What causes planetary carrier or gear tooth wear in heavy extruder back-drives?
Planetary back-drives in plastic extruders run under continuous high torque and thermal stress. Wear on carrier splines and planet teeth is often caused by sun gear micro-misalignment or degraded lubrication viscosity under extreme heat. We resolve this by overhauling the planetary carrier assembly, re-cutting the splines, replacing worn pinions, and setting precise backlash clearances to redistribute load forces evenly.
One Call Restarts Your Entire Line
Zero downtime. Bulletproof gears. Guaranteed.
Ready for a gearbox that never fails again?
(832) 860-5493
Email: INFO@DIRECTMAINTENANCESERVICES.COM
