How to Lubricate an AEG Gearbox After a Rebuild

Question:

How do I properly lube an AEG gearbox after a full rebuild?

Answer:

Proper lubrication after a gearbox rebuild is essential for longevity, performance, and smooth cycling. Using the wrong lubricants or applying too much can cause serious damage, so understanding the basics matters.

Gear Lubrication:
Apply a thick grease, such as white lithium or silicone-based gear grease, directly onto all gear teeth. A thin, even coat is sufficient. Avoid petroleum-based products, as they can degrade plastic and rubber components over time.

Cylinder and Piston:
Use a thin silicone oil or silicone grease lightly applied inside the cylinder walls. Apply a small amount to the piston head O-ring to maintain an airtight seal. Avoid over-lubricating, as excess oil can pool and cause hydraulic lock.

Bushings or Bearings:
A tiny drop of light oil on each bushing or bearing point helps reduce friction and heat during operation. Less is more here.

Spring and Spring Guide:
A very light coating of grease on the spring helps reduce noise and wear. Some technicians prefer leaving the spring dry to avoid attracting debris.

Motor Pinion Area:
Apply a minimal amount of grease where the pinion gear contacts the bevel gear.

After assembly, run the gearbox through several slow cycles before full-speed testing. Listen for unusual grinding or clicking sounds, which may indicate misalignment or insufficient lubrication. Regular maintenance every few thousand rounds keeps internal components performing reliably and extends the overall life of your AEG significantly.