6-84260 SD40 front coupler - exploded view diagram?

I also have the 84260 very cool loco, the bell placement is one of my favorite parts.

The electrocoupler is held to the pilot by the screw coming up from the bottom. Remove and replace all the parts in the same order and tighten screw. The spring is there to keep the coupler centered. The wires are tucked into a channel in the frame using 4 small screws and 2 small pcs of thin flat metal, these will need to be removed and reinstalled also. Make sure you leave enough slack in the wiring for the pilot and coupler to swing from side to side. In order to connect the electrocoupler plug to the RCDC board you will have to remove body and pull wire connector through the hole that the existing electrocoupler wires are ran through.

What is the reason for replacement if I may ask? 

thanks - will put it back together - the reason for replacement is that I took it out of the box(bought new) and the coupler was loose and on the btm of the box, there were two wires sticking out - the crew that holds it in place and the washer were in the coupling - when i reconnected the wires it did not work - i also tries contacting Lionel for service and never got a reply or return call after four or five tries.  i will try to reinstall the new coupler and see if it works - PS i think the Unit was under warranty but did not get any help from Lionel.  thanks for your help

ted

Oh ok since it was loose in the box you may not know the order the parts go back on. I can pull my coupler apart and post a pic showing the order the parts go back on when I get home from work today.

thats ok - almost done putting it together - will test it in a few minutes - appreciate your help - will let you know how it works

Ted,

    Here is a tread where dave Olson had a diagram of how the coupler is positioned.

                 https://ogrforum.ogaugerr.com/...87#77311805257450687

JohnB

Thanks John - that confirms what i need to do - have reassembled the coupler and it works fine!!   looking  through the trend from Dave Olson - is seems like others had the couplers loose with the screws in the box - mine had the wires broken as well - but all is well now -  thanks 

thanks to all that helped - the new coupler is in place - spring and screws all made it back to the right spots - ran the engine a few times and the coupler works fine - wish i got a response from Lionel though-that is disappointing

I've seen Lionel put foam inserts on each side of the electrocoupler on other locomotives. I'm not sure why they don't do it on the SD40. If the loco is laying on it's side in the mail truck the coupler will shake itself loose from the vibration.

thanks - but i find it hard to believe that the wires were broken as well - i guess if the coupler could have come loose and dangled in place - but not sure how it could have found itself at the btm of the box, inside of the packing material and the wires broken.  very strange,  i think someone didn't tighten the coupler and broke it off when putting it in the box - but all is good now - i have a tight coupler and it responds to the Legacy commands properly.  still upset  with Lionel not responding to my emails - i even said I would have paid for the service and asked them what i could do - absolutely no response!  i guess they are too busy doing videos.