How to Replace Clock Gears Without Causing Damage

Replacing clock gears may sound intimidating, but with the right approach, tools, and care, you can do it successfully and extend the life of your clock. Whether you’re working on a grandfather clock, wall clock, or mantel clock, knowing how to replace clock gears without causing common damage will save you time, money, and frustration. This article will guide you through each step to ensure a smooth and careful gear replacement.

Step 1: Understand Why Gear Replacement Matters

Mechanical clocks rely on a system of gears that transfer power from the mainspring or weights to the hands and chime mechanisms. Over time, gears can wear out, develop bent teeth, or even break. If you continue to run a clock with damaged gears, you risk damaging other parts of the movement, including pivots, bushings, and the escapement.

Replacing worn or damaged gears restores proper operation and protects the rest of the movement. But you must use the right method and tools — otherwise, you can accidentally create more problems than you solve.

Step 2: Gather the Right Tools

Before you begin, assemble the proper tools:

• Small screwdrivers (flat and Phillips)
• Clock hand puller or remover
• Pliers with smooth jaws
• Clock mainspring let-down tool (if needed)
• Calipers or micrometer
• Lubricating oil (for reassembly)

Clockworks offers a full selection of specialized clock tools designed for safe disassembly and repair.

Step 3: Remove the Clock Movement Safely

Carefully remove the movement from the case. Take photos of each step to document how everything fits together. Remove the clock hands using a hand puller, and set them aside. If the clock has weights or a pendulum, remove them next.

Disengage the mainspring or let down the power before you remove gears. This step is critical — if you fail to release tension, you can damage the movement or injure yourself when gears snap loose.

Step 4: Inspect the Gears

Examine the gears closely under good lighting. Look for:

• Worn teeth
• Bent or broken teeth
• Cracks or warping
• Loose or damaged pivots

Identify which gears need replacement. Measure the diameter, tooth count, and arbor size with calipers or a micrometer to ensure you order the correct replacement gear.

Step 5: Remove the Damaged Gear

Use a gear puller or wheel puller to remove the gear from its arbor or post. Work slowly and steadily — never pry or force a gear off, as this can bend arbors or crack plates. If the gear has a friction-fit, gently wiggle it free using smooth-jawed pliers.

Keep all small parts, screws, and washers labeled and organized in small containers. This will make reassembly much easier.

Step 6: Install the New Gear

Once the damaged gear is out, install the replacement. Align the gear on its arbor or post, and gently press it into place. Avoid using a hammer or tapping force, as this can bend the arbor or crack the plate. If necessary, use a small arbor press or clamp with even pressure.

Check that the gear spins smoothly without wobble. Make sure it meshes correctly with the surrounding gears.

Step 7: Check the Gear Train

After replacing the gear, turn the gear train slowly by hand. Check that all gears mesh smoothly and that no teeth catch or bind. This step helps you catch any alignment issues before reassembling the entire clock.

Step 8: Reassemble the Clock

Reassemble the clock movement in reverse order. Lubricate pivots and bushings with clock oil, using only a tiny drop at each point. Avoid over-oiling, as this can attract dust and cause wear.

Reinstall the movement into the case, reattach the clock hands, and reinstall the pendulum or weights. Make sure everything is secure before testing the clock.

Step 9: Test the Clock

Once reassembled, wind the clock or reinstall the weights and let it run. Watch for smooth, even movement of the gears and hands. Listen for irregular sounds that may signal misalignment or friction. Let the clock run for at least 24 hours to ensure stable performance.

Step 10: Maintain Proper Care

To prevent future gear problems:

• Clean and oil the movement every 2–3 years
• Keep the clock away from moisture and dust
• Check for signs of wear regularly
• Avoid over-winding or forcing the mechanism

Proper care and routine maintenance will extend the life of your clock and reduce the need for future repairs.

Common Mistakes to Avoid

Skipping the power let-down — Always let down the mainspring or weight before disassembly.

Using force — Never hammer or force a gear into place.

Mismatching gears — Always measure carefully to match the replacement gear.

Skipping testing — Always test the gear train before full reassembly.

Summary

Replacing clock gears is a delicate but manageable task when done carefully. By using the right tools, measuring accurately, and handling parts gently, you can replace worn or broken gears without causing additional damage. Take your time, follow each step, and don’t rush the process. When you need high-quality replacement gears or clock tools, visit Clockworks.com or contact clockworks@clockworks.com — we’re here to help you keep your clocks ticking beautifully.

Updated on: 12/07/2025