Direct Maintenance Services
Industrial Gear & Gearbox Repair
24/7 Emergency
Free Pickup
Minimal Downtime
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
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Industrial Gearbox & Gear Reducer Repair
D.M.S. is the nationwide authority 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, bulletproof rebuilds that routinely outlast new OEM units by 5-10x. We also service complementary powertrain components like industrial process pumps and rotary lobe blowers.
Detailed 15-Step Gearbox Rebuild Process
Comprehensive 9-Step Gearbox Rebuild Process
1. Free Nationwide Pickup
Insured, zero-cost transport
2. Teardown & Inspection
Digital as-found report & CMM measurement
3. Cleaning & Ndt
Glass-bead cleaning & magnetic particle inspection
4. In-House Gear Machining
CNC hobbing, shaping & profile grinding
5. Shaft Restoration
Straightening & hardened bearing journals
6. Premium Upgrades
Upgraded seals & premium bearings
7. Precision Assembly
Dynamic balancing & laser alignment
8. Full-Load Test Cell
Vibration, temp & noise verification
9. Free Return Delivery
12-36 month warranty starts
Top 18 Gearbox Failure Modes We Fix
Top 9 Gearbox Failure Modes We Fix
Bearing Failure
Symptoms: Noise, heat. Cause: Lack of lube, overload.
Tooth Pitting & Fracture
Symptoms: Metal in oil. Cause: Fatigue, shock load.
Shaft & Keyway Damage
Symptoms: Slippage, vibration. Cause: Over-torque.
Overheating & Contamination
Symptoms: High temps. Cause: Water/metal ingress.
Seal & Housing Wear
Symptoms: Oil leaks. Cause: Worn seals, bearing spin.
Misalignment
Symptoms: Severe vibration. Cause: Poor installation.
Spline & Backlash Issues
Symptoms: Power loss, shock. Cause: Excessive wear.
Lube System Failure
Symptoms: Dry running. Cause: Blocked pump/breather.
Carrier & Worm Wear
Symptoms: Loss of ratio. Cause: Component fatigue.
150+ Gearbox Brands We Service
Cooling Tower Speed Reducers & Fan Drives
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.
Gearbox Types We Rebuild
From FDA-compliant sanitary environments to extreme abrasive mining conditions, we have the specialized tooling for your exact application.
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.
In-House Gear Manufacturing
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
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
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
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 micro-misalignment of the sun gear 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
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Email: INFO@DIRECTMAINTENANCESERVICES.COM
