Garage Door Operator Drive Gear Assembly Replacement
In this guide, we will be going over how to replace your drive gear along with the how’s and why’s. We are confident that this will help you refine your skills as an installer and better service for your customers.
How do you know the drive gear needs to be replaced?
The drive belt and gears occasionally wear out. The signs to look out for are:
- The operator is running but not opening and closing the door.
- When you take off the cover of the operator, you will see white shavings from the worn-out gear.
How did this happen?
Drive gear can wear out due to overall usage but typically, there is a problem in your system. Make sure to check the entire door operation before simply installing a new drive gear. To do this, simply:
- Open and close the door by hand to check door balance. Make sure it opens and closes smoothly.
Typically, breakdowns happen from operating a door with broken springs or an improperly balanced door. These issues can create serious stress on the drive gear and cause it to wear down much quicker.
What drive gear kits are available?
- This kit is the most popular and works for all chain-drive gear assemblies from 1984 to present.
- Another popular option for chain-drive gear assemblies. This will require you moving the pins instead of the entire housing.
- These models are for belt-drive operators as well as ATS operators.
Using proper OEM replacement parts is essential to continue all additional warranties for the operator as well as ensuring proper operation.
Here is a step-by-step guide at assembling the LiftMaster 41C422 on your operator.
- Irwin Vise Grip Pliers
- ½” Wrenches
- 5/16” Speed Wrench
- Drive Pins
Make sure to check the model and serial number on the back of the operator to ensure you have the correct part for this repair.
Also, check if the operator is belt drive or chain drive before starting your repair
- Pull the manual release on the door. Be aware that the door may not stay in the open position if the spring is worn out.
Pro Tip: Attach Vice Grips to the trolley to make sure it does not move when loosening the chain. This will keep the travel within proper limitation of the assembly.
- With the ½” wrenches, loosen the nuts that hold the assembly, so you can loosen the chain from the drive sprocket.
- Take off the plastic clip on the bottom of the shaft, allowing you to remove the small plastic gear. Take off the screws that hold the housing to the operator.
- Pull out the assembly from above. With the assembly out, we can now focus our attention on the worm gear that is on the drive shaft of the motor.
- Remove the RPM sensor cap at the end of the motor shaft and check if the RPM sensor needs to be replaced.
- On the drive shaft, remove the clip that holds the washers and housing in place then, remove the washers and the metal collar.
- Slide the motor out and replace the worm gear. Once the new worm gear is on, set the motor in place and put on the new metal collar.
- Once done, tighten the three bolts to secure the motor in place, then put the washers and set pin back on the drive shaft. Finally, put the rpm-sensor cap back on the end of the motor shaft.
- On the new gear, take off the lower plastic clip and the small gear from the new assembly and lower it into place from above.
- Once in place, secure the housing to the operator’s head, put the new small drive gear on and set the plastic clip into position.
- Now, it’s time to lube the gears. The lube is supplied within the packaging and must be used. Spread the lubricant around the gears and then rotate them using the rpm-sensor cap.
Remember: Make sure to keep the housing screws as the new kit does not have them.
You are now done! Make sure to reinstall the chain and tighten everything up. Finally, release the vice grips that were holding everything in place and put the cover and back panel back on.
We recommend running the operator on manual to make sure the travel adjustments are the same. Make the necessary adjustments to your travel limits and always check your safety reverse settings.
To watch the full video, along with other helpful videos, be sure to check out all our Solutions Education courses.
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Safety Disclaimer: In order to see all procedures completely, there may be safety measures that are not taken by our actors. Be sure to follow any and all proper safety requirements and refer to your manufacturer’s installation manual for details. Your health and safety is the #1 concern. Failure to understand/follow the recommendations in the course could result in property damage, personal injury or death. While all efforts are made to provide accurate information and guidance, it is impossible to predict all door circumstances. Accordingly, the user agrees that the user of this video; products and information contained herein are at your own risk. In no event shall Service Spring be liable for any property damage, personal injury/death, or any other loss or damage that may result from your use of the information and products provided on this video. All information contained within this site is provided “as-is” without warranty expressed or implied. User assumes all responsibility/risk for use of information and products purchased. If you have any doubts about your ability to perform the work safely, we recommend you contact another door professional to complete your repair.