Parallel shaft helical gearing
A-Plus, Type A and V-Class helical gears inspected flank by flank, reground where possible and recut in house where not.
Texas · Falk enclosed drive repair · nationwide 24/7
Falk Gearbox Repair and Rebuild
Falk drives are everywhere heavy material moves: conveyors, crushers, mills, kilns, pulp and paper lines, and wastewater plants. They are tough, which is exactly why a failed Falk gearbox is usually old, loaded hard, and out of the OEM parts window. We are a family owned Texas gear shop, established in 1998, and we repair and rebuild Falk enclosed drives in house as a practical alternative to long OEM lead times. Parallel shaft and right angle units, shaft mounted drives, and the big mill reducers, we tear them down, find the real root cause, and put them back together stronger than they left the factory. See our full gearbox repair capabilities for the bigger picture.
Yes, we repair and rebuild Falk gearboxes. Solution Gear Co. is an independent Texas gear shop that rebuilds Falk parallel shaft, right angle and shaft mounted enclosed drives as an OEM alternative, with all work done in house, free shipping both ways, nationwide 24/7 emergency service, and up to a 24 month workmanship warranty.
Falk has built enclosed gear drives in Milwaukee since the 1890s, and the brand now lives under Regal Rexnord. The installed base is enormous, which means a lot of Falk units in service today are decades old, run past their original duty, and increasingly hard to source parts for. Most of what we see is the same handful of failure patterns: bearing fatigue, tooth flank pitting from overload or degraded oil, worn shafts and bores, and seals that let the oil out. We have built our process around catching all of it before we quote a single part.
Distance is not a problem. We offer free shipping both ways, free pickup and delivery including crating and rigging, and a free inspection before you commit to anything. Whether your Falk drive runs a quarry conveyor, a ball mill or an aeration blower, send it in and we will tell you exactly what is wrong. For mill and crusher duty in particular, see our mining equipment page.
Falk units we repair
Falk built a broad catalog over more than a century, and we have had most of it on the bench. We service the full range as an independent shop, including the families below.
- Falk A-Plus and Type A parallel shaft drives. The classic helical parallel shaft reducers found on conveyors, mixers, agitators and process lines. Single through quadruple reduction, often decades old and still worth rebuilding.
- Falk V-Class drives. The newer generation of parallel shaft and right angle units that replaced the older families in many plants. Same failure modes, tighter tolerances.
- Falk Quadrive shaft mounted drives. Shaft mounted helical reducers that hang directly on a conveyor or fan shaft. Output bearings and the hollow shaft bore take the punishment.
- Right angle bevel helical units. Bevel and bevel helical drives that turn the corner in tight installations. The spiral bevel set decides the life of the unit.
- Large mill and kiln reducers. Heavy duty Falk gear drives on ball mills, rod mills, rotary kilns and dryers, where a failure stops the whole plant and there is rarely a spare on the shelf.
If your unit is not on this list but it says Falk on the tag, send it anyway. We cut our own gears, so we are not limited to whatever happens to be in a parts catalog. See our gear cutting work.
How Falk drives actually fail
Falk equipment is well built, so failures almost always trace back to load, lubrication or time, not to bad design. These are the conditions we find most often on Falk units that come through the shop.
- Bearing fatigue. After enough hours under load the races spall, the rollers skid, and heat and metal in the oil follow. On shaft mounted drives the output bearings go first because they carry the belt or fan load directly.
- Tooth flank pitting and spalling. Overload, misalignment and degraded oil cause pitting on the helical and bevel tooth flanks. Left alone it grows into spalling and broken teeth. We inspect every flank for wear pattern and contact before deciding what gets reground and what gets recut.
- Hollow shaft and bore wear. On Quadrive style units the hollow output shaft and its bushing fret against the driven shaft, and the bore goes out of round. The unit gets loose, noisy and hot.
- Seal failure and lube starvation. Worn seals leak oil, drop the level, and quietly starve the gears and bearings. By the time the leak is obvious the internal damage is often already done.
- Housing cracks and bore distortion. Old cast housings crack at the feet and bearing bores lose their fit. We weld repair and line bore rather than scrap a housing that may no longer be available.
Because so many Falk failures start at the bearings, we treat bearing work as its own discipline. See our bearing repair page.
How we rebuild a Falk gearbox
Every Falk unit follows the same disciplined path through our shop, and it starts with a free, no obligation inspection.
- Teardown and inspection. We fully disassemble the unit, clean every part, and inspect gears, shafts, bearings, seals and the housing for wear, pitting, cracks and bore distortion. You get a written findings report before we quote.
- Root cause first. We do not just swap the broken part. We figure out why it broke, whether that is alignment, overload, lubrication or a worn upstream component, so the rebuild actually lasts.
- Machining and gear work. Minor flank wear gets reground. Severely worn or broken gears get cut new on our own machines. Worn shafts and bores are built up and machined back to spec, and housing bores are line bored true.
- Stronger than OEM. We rebuild with premium bearings and seals and, where it makes sense, upgraded materials and heat treatment so the unit comes back tougher than it was new.
- Test and document. The unit is reassembled to spec, checked for backlash, contact and runout, and documented before it ships.
All of this happens under one roof in Houston, Texas, which is how we hold quality and keep turnaround honest. Line down right now? Our emergency line is answered 24/7, and we ship nationwide.
Independent Falk service, free shipping both ways
We are an independent gear repair shop. We are not an authorized Falk dealer or service center and we are not affiliated with the Falk brand or its owners. We name Falk only to describe the equipment we service, and we repair and rebuild these units as an OEM alternative for plants that need them back in service without OEM lead times.
Because we ship free both ways and handle pickup, delivery, crating and rigging at no charge, it does not matter whether your plant is in Texas or across the country. The inspection is free and there is no obligation to proceed. If you want to see the kind of heavy industrial work we do every day, our industries and brands pages cover the rest of the equipment we keep running.
Up to a 24 month workmanship warranty backs every rebuild, which is our way of standing behind the fact that the unit really did leave here right.
What we repair and rebuild
What we fix.
Shaft mounted drive rebuilds
Quadrive and similar shaft mounted units rebearinged, hollow shafts and bushings restored, and output bores brought back to fit.
Spiral bevel gear sets
Pitted or broken right angle bevel sets reground or cut new and reset to correct contact pattern and backlash.
Mill and kiln reducers
Large Falk mill drives torn down, inspected and rebuilt with gears cut to the original geometry.
Worn shafts and splines
Input and output shafts, splines and coupling bores built up and machined back to spec to restore alignment.
Seals and lubrication
Leaking seals, contaminated oil and starved bearings corrected so the rebuilt unit stays cool and properly lubricated.
Housing and bore repair
Cracked, worn or distorted housings welded, line bored and machined true so bearings and gears seat correctly.
Obsolete unit reverse engineering
Older Falk families with no parts support measured, drawn and rebuilt in house.
Common questions
What plants ask us.
Do you repair Falk gearboxes if we are not in Texas?
Yes. We ship free both ways and cover pickup, delivery, crating and rigging at no charge, so your location does not matter. Plants across the country send us Falk drives, and our emergency line answers around the clock.
Are you an authorized Falk or Rexnord service center?
No. We are an independent gear repair shop and we are not affiliated with Falk, Rexnord or Regal Rexnord. We repair and rebuild these units as an OEM alternative and name the brand only to describe the equipment we service.
Can you rebuild an older Falk drive that is no longer in the catalog?
Yes. That is a large part of what we do. We measure the existing gears and shafts, draw them, and cut new ones in house to the original geometry, so a discontinued unit can still be rebuilt.
What fails most often on a Falk shaft mounted drive?
The output bearings and the hollow shaft bore. They carry the belt or fan load directly, and once the bearings spall or the bore frets loose the unit runs hot and noisy. We rebearing the unit and restore the bore to fit.
What does a Falk rebuild cost and how long does it take?
It depends on what we find during the free inspection. We send a written findings report and a firm quote before any work begins, so you know the cost and the timeline before you commit. There is no obligation to proceed.
Get your Falk gearbox back in service
Free shipping both ways, free inspection, and an up to a 24 month warranty on every rebuild. Family owned in Texas for over 20 years, answering the emergency line 24/7 and shipping nationwide. Tell us about your unit and we reply fast, often the same day.
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