Eternal Gear Rebuilders specializes in expert repair and rebuild of Rexnord Falk, Rex, and Thomas gearboxes. Trust proven Rexnord expertise to restore your critical drive systems.
Rexnord gearboxes are engineered for demanding industrial applications—from heavy-duty mining and cement production to pulp & paper and steel processing. Their reputation for durability is well-earned, but years of continuous operation under load inevitably lead to gear tooth pitting, bearing wear, and seal degradation. Eternal Gear Rebuilders understands Rexnord's unique engineering specifications, helical and spur gear configurations, and shaft alignment tolerances across all three product lines. We diagnose root causes, source authentic components, and rebuild your Rexnord to OEM performance standards—keeping your facility running without the downtime of factory service centers.
Eternal Gear Rebuilders brings decades of focused experience to every Rexnord repair. Our technicians are intimately familiar with Falk planetary and parallel-shaft configurations, Rex high-speed gearboxes, and Thomas spiral bevel designs—including the subtle engineering differences that distinguish each product line. We maintain access to Rexnord OEM specifications, bearing and seal cross-references, and genuine component suppliers, eliminating guesswork and ensuring your rebuilt gearbox meets factory tolerances. Our systematic diagnostic approach identifies the root cause of failure—misalignment, lubrication breakdown, or material fatigue—so we repair it right the first time and help prevent recurrence.
Even the most robust Rexnord gearboxes eventually succumb to operational stress. Understanding these failure patterns helps you recognize when professional rebuild is your best option:
Rexnord Falk and Rex helical gears experience cumulative fatigue under continuous high-load operation. Micro-pitting initiates at tooth roots under inadequate film thickness, progressing to macroscopic spalling that cascades across the gear face. This is especially common in Falk parallel-shaft units operating above rated torque or with contaminated lubrication. Audible clicking, vibration spikes, and metallic particles in oil are warning signs.
Rexnord gearboxes depend on precision deep-groove and cylindrical roller bearings to maintain shaft alignment and load distribution. Extended operation, moisture ingress, or inadequate bearing preload lead to premature wear, increased backlash, and eventual cage failure. Excessive runout directly accelerates gear mesh wear and can crack the aluminum housing in extreme cases—particularly in Thomas spiral bevel designs where bearing concentricity is critical.
Rexnord seals are designed for moderate pressure and thermal stability, but oxidized, overheated, or water-contaminated lube oil causes premature elastomer degradation. Weeping at the output or input seal is often the first indication that oil has broken down and internal corrosion is already underway. Rapid seal failure can allow abrasive particulate to invade the gearbox interior, causing secondary bearing and gear damage within days.
Rexnord input and output shafts endure rotational stress, shock loads, and thermal cycling. Spline wear develops when coupling misalignment induces edge loading, while keyway corrosion occurs in humid environments or due to saltwater contamination in coastal or marine-adjacent facilities. Shaft straightness loss of even 0.005" transforms harmless vibration into bearing-destroying runout, making timely intervention critical.
Our proven four-step methodology ensures every Rexnord gearbox returns to service at full performance capacity:
We carefully disassemble your Rexnord gearbox, documenting component positioning and condition. Gear face patterns are analyzed for pitting severity, bearing races inspected for spalling, shafts checked for runout and corrosion, and housing examined for micro-cracks. High-resolution photography and detailed logs establish baseline damage and guide the rebuild scope.
Every gear is probed to 0.0001" tolerance using coordinate measuring machines; bearing bores are checked for concentricity and surface finish; shafts are spun on precision spindles to detect runout. We perform metallurgical assessment where appropriate and compare findings against Rexnord OEM specifications. This diagnostic rigor reveals whether failure stemmed from design limitation, installation defect, maintenance lapse, or material fatigue—critical knowledge for preventing recurrence.
Teeth with minor pitting are honed; severely damaged gears are replaced with Rexnord OEM or equivalent components. Bearings are renewed to OEM specifications; seals upgraded when applicable. Shafts are precision-ground, spline teeth are restored via EDM or specialized honing, and keyways are repaired. All components are cleaned and prepped in controlled environments to prevent contamination.
Your gearbox is reassembled using calibrated torque wrenches and proper fastener techniques. Bearing preload is set per Rexnord engineering, shaft runout is verified below 0.002" TIR, and gear backlash is adjusted within specification. A final bench test—under load simulation where applicable—confirms smooth operation, noise signature, and thermal stability before shipment.
When your Rexnord gearbox fails, you face pressure to minimize downtime while ensuring long-term reliability. Here's why maintenance teams trust us:
Our technicians have rebuilt hundreds of Falk, Rex, and Thomas gearboxes across all common configurations—parallel-shaft, planetary, spiral bevel, and helical designs. We know the failure patterns unique to each product line, the supplier-specific bearing and seal tolerances, and the OEM engineering specifications that guarantee your gearbox performs as intended.
We source from authorized Rexnord distributors and vetted equivalency suppliers, ensuring every replacement gear, bearing, seal, and fastener meets Rexnord specifications. No compromises, no off-spec aftermarket components that degrade performance or create liability risk. Full traceability and material certifications included.
Rexnord factory service centers juggle national capacity constraints; we prioritize your rebuild schedule. Most Rexnord gearboxes are rebuilt and tested within 2–3 weeks, often faster than obtaining a replacement unit. Our proximity and direct communication eliminate the coordination delays typical of larger OEM service networks.
When Rexnord gearbox issues involve motors, pumps, or electrical systems, Eternal Gear Rebuilders handles all disciplines under one roof.
Industrial motor repair, rewind, and performance restoration.
Motor RepairComplete mechanical rebuild — overhaul, lifecycle extension, OEM-spec restoration.
Machine RebuildingPump repair and rebuild for all industrial equipment types.
Pump RepairIndustrial electrical troubleshooting, VFDs, starters, and control panels.
Electrical ServicesYour Rexnord gearbox is too critical to entrust to a generalist shop. Eternal Gear Rebuilders combines specialized Rexnord expertise with precision manufacturing and rapid turnaround—so your facility gets back online fast without sacrificing quality. Contact us today for a free diagnostic assessment and competitive rebuild quote on your Falk, Rex, or Thomas gearbox.
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