Gearbox Rebuild vs. Replacement: What Saves You More in 2025?

When an industrial gearbox fails, your first question is: rebuild or replace? In many cases, a professionally rebuilt gearbox performs just as reliably as a new one—at less than half the cost. But the right decision depends on condition, lead time, and application risk.

Cost Comparison Over 5 Years

Here’s a typical cost curve comparing rebuild vs. replacement over five years, including maintenance and lifecycle costs:

When a Rebuild Makes Sense

• The gearbox housing and core components are structurally sound
• Downtime costs are high — rebuild is faster than ordering new
• Parts are available or easily machined
• The gearbox is custom-built or has a long lead time

When Replacement is the Smarter Option

• Catastrophic failure has damaged casing, shafts, or gear trains
• It's cheaper to install a modern, energy-efficient model
• Maintenance costs have increased year-over-year
• The existing unit is obsolete or unsupported

What We Do in a Gearbox Rebuild

Our overhaul process includes complete disassembly, inspection, and replacement of all bearings, seals, and damaged gears. We perform precision machining and shaft straightening, and test for alignment, balance, and thermal performance before return.

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