@James B posted:I’m going to focus on the rollers and springs first to see what I can do. I’ve learned a lot about repairing these things, but I’ve never tinkered with the springs. Is it a tough job?
Well..
@bmoran4 posted:Depending upon your abilities, you can replace only the spring, the pickup assembly, the coupler plate, or the truck as a whole.
Let us reference this parts exploded view:
Replacing the Spring (only) - Some claim this can be done by unraveling the old TCL-45 spring from around the mounting TT-234 rivet and installing the new one the same way, kinda like a key on a key chain. To some, this is desirable because it doesn't require any special tools, soldering, or riveting. While you can damage/cut off the old spring to make removal easy, installation with this method can distort or damage the new spring. Good news is the spring is cheap, so you buy a bunch and build up your skill.
Replacing the Pickup Assembly - You remove (drill out) the 480-19 rivet releasing the existing 481-6 pickup roller assembly. Access to do this operation requires removal of the 482-3 or 481-10 coupler base plate which is held on by metal tabs wrapped around the axles. You carefully bend the tabs minimally to release the plate or you can gently spread the bolsters to drop the axles out releasing the base plate. The tabs can break, the bolsters loosen, and the repair quality can suffer. You also will need to de-solder the pickup wire or cut it off from the existing pickup assembly. Now, you take your new 481-6 pickup roller assembly and use your new 480-19 rivet to install to the base plate. This requires a rivet setting tool such as Brakeman's Riveter or the Arbor press with the appropriate Lionel or Hobby House dies. Yeah, a punch may do it, but not as cleanly and nicely. Solder the pickup wire to the pickup assembly and reinstall the base plate.
Replacing the Coupler Base Plate - Just like above, you release the old base plate by bending the metal tabs, but since you have a new 482-3 or 481-10 base plate, it doesn't matter if one or more of the tabs break off. Use pliers to bend the tabs of the new base plate around the axles.
Replacing the Truck - Replacing the truck as a whole works well. I believe the 746W tender uses the 482-1 truck in the front and the 481-1 in the rear. Remove the shell and loosen the whistle from the frame to gain access to the truck studs that are held in place with the 480-18 horseshoe clips. Use pliers or a screwdriver to remove the clips to drop the trucks out. Be sure to order new 480-18 clips in the event the existing one are mangled on removal. De-solder or cut the pickup wires from the old pickup assembly. Solder the wires to the new trucks and install the trucks to the frame with new or reused 480-18 clips. Refasten the whistle to the frame. Reinstall the shell.
I generally go with the last two repair methods as the parts are inexpensive enough compared to the time it takes and risks of getting stuck due to causing more damage.
