(Topic ID: 28201)

If your TOM trunk is acting up clean the gear box....junk in the trunk

By cal50

11 years ago


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#1 11 years ago

I was getting random trunk errors but would clear and run fine after "trunk test". My trunk was also getting loud when rotating and had a little side play in it as well.

The fix is cheap and easy and man what a difference.....

I pulled the trunk gearbox and the factory grease was like sticky taffy. Also the main shaft is attached by two set screws which were loose and that is where the trunk wiggle came from. I cleaned the gear box and gears completely by using carb cleaner to remove all the old gunk. I then greased and put the gears and box back together using a synthetic grease with teflon. Once I got everything back together I could not believe how much faster the trunk rotates and is REALLY quiet. I would bet that thick grease is responsible for some motor failures.

If you are shopping your game its worth the effort to clean and grease the gearbox.

#2 11 years ago

A mini how to-

Really the only crap part it pulling the wires through the shaft that the trunk rotates on. You can either cut them and re-solder the 4 wires ( 2 separate Molex connectors) of if you have a molex pin removal tool you can pop them out and back in without cutting them. I have a pin tool from radio shack for the large pins and cut and solder the smaller wires for the trunk green light.

In a nut shell-

Remove 4 screws from top of trunk.
Remove plastic trunk
Unplug magnet molex connector
Disconnect the wires that come out of the bottom of the trunk shaft. Cut or remove pins and pull thru and out the top of the trunk.
Remove plastic opto interrupter from bottom of shaft
Use a 3/4 open end wrench and remove the 2 jamb nuts that hold the trunk frame on the shaft. Remove trunk frame assembly
Unplug trunk motor and opto board connector
Remove 4 nuts and remove opto board.
Remove 3 nuts / 1 screw (mine) and take off the motor and gear box assy.
Loosen set screws on shaft collar , I used a sharpie marker and made a couple dots on it and the bracket to remember how it came apart
Remove screws and take gearbox assembly off of bracket.

Gearbox has several Torx screws holding the case together, remove as needed to open gear box.
There are a few gears but noting major. Make a note, take a picture or use your marker to remember how they go in / come out.

Clean with carb cleaner, re-grease gears and place back in gear box.
Make sure the two set screws are tight where the main shaft goes thru the gear box gear.
Mine was loose and part of the original problem.
Put box back together and tighten Torx screws
Align collar on shaft and tighten 2 set screws.
Put gearbox back on bracket, etc. , etc.

I might have missed something but you get the idea.

Use a swab and some Windex and clean your opto's while the board is off and make sure your solder connections are OK.

#6 11 years ago

It sounds harder than it really is and WELL worth the time it takes. I thought my motor was on its way out and was making plans to buy a replacement and this was a pleasant surprise.

About a 2 beer job.....

#8 11 years ago

This-

Grease.jpgGrease.jpg

#11 11 years ago
Quoted from BillP:

I have 2 beers, come to Cleveland....thanks for the tip.
Very appreciated.
Bill

I am close.....over in Amherst,

~Jeff

3 weeks later
#14 11 years ago
Quoted from Engine09:

Disassembled my trunk and opened up the gearbox tonight. I've been noticing that the motor/gears are making more noise than usual so was concerned. Everything actually looks alright, decent amount of grease still in there and everything turns alright.
How dirty or dry were your gears when you cracked the case open?

It was the old grease that was sticky and thick. It was like molasses in my gear box. It did not seem to awful bad at first but after I sprayed it all away with carb cleaner and use the grease I mentioned above it was a WORLD of difference. My trunk is quiet and more importantly it rotates a LOT faster.

If you split it apart I hope you cleaned and lube it going that far.

2 weeks later
#21 11 years ago
Quoted from markmon:

Quick question. Where do you apply the grease? On the rods before slipping the gears back on? On the gear teeth?

Yes.
All contact points and on the face & sides of the gears as well.
It made my trunk is REALLY quiet and a lot faster turning.

I should have taken some pics or been a little more scientific and used a torque wrench and recorded the torque before Vs after for turning force required after clean and lube.

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#23 11 years ago

Lightly coated.

The gummy / sticky old grease is the killer.

#26 11 years ago

What John said.....

Clean out all of the old gunk and coat everything with a light coat of new grease. Gears (all surfaces) shafts, case where the gears ride, etc.

#27 11 years ago
Quoted from johnwartjr:

Everything. It will have turned from lube to nearly varnish consistency.
Here's a MB Drac Gearbox tutorial - from 98. Check out the dried out grease:
http://iobium.com/rebuilding_the_monster_bash_drac.htm
And an I500 gearbox:
http://gallery.myhomegameroom.com/gallery/i500_racetrack_gearbox

Nice pics and my old grease looked just as nasty.

#31 11 years ago
Quoted from kmoore88:

Inside of Trunk Motor assembly.

Yep, that is the same nasty gear box I had on mine!

Once clean make sure the two (2) set screws are tight on the gear / shaft or your trunk will wobble side to side and you will take it apart again.

Its amazing how much quicker you can do it the 2nd time.....

(Good pics)

4 months later
#41 10 years ago
Quoted from Syco54645:

where did you find the superlube? I have been looking for it for years. I know I can order it online. Maybe that is the only option?

I ordered a bunch of it.

1 year later
#48 9 years ago
Quoted from robbiedoo:

Sorry for the revival, but I NEEDED to say that this is an incredible must-do!
I was having issues with my trunk 'shifting' out of position when hit by the ball, and came across this thread. I took its advice and found that my gearbox had some really nasty buildup.
This task was fairly easy to do and made such an improvement in the way my ToM's trunk works, smoother, quieter and my issue was fixed.
I just wanted to say a huge thank you to cal50 for suggesting this, and throw my recommendation behind doing this to any ToM that hasn't had it done yet.
Here's my gunk:

unnamed.jpg 54 KB

unnamed2.jpg 78 KB

Nice pics!

The process sounds a lot worse than it really is and its a good "tune up".
Its one of those cheap fixes that costs little but can make a huge difference.

All that old grease and crud has to be putting a lot more drag on the small motor.....

10 months later
#59 8 years ago

That sludge is harder on a motor.....new or old.

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