Rebuild, Reman Or New Travel Gearbox — What’s The Smart Upgrade?

When a travel gearbox in your excavator or other heavy machinery begins to show signs of wear or declining performance, operators and fleet managers are often faced with a crucial decision: should you rebuild the existing unit, opt for a remanufactured gearbox, or invest in a brand-new unit? This choice is more than just a maintenance decision—it can have long-term implications for uptime, operational efficiency, and total cost of ownership. At LB, a leading manufacturer and supplier of earth-moving machinery components, including travel reducers and swing reducers, we understand the unique challenges faced by operators in construction, mining, and heavy industrial projects. This guide provides an in-depth comparison of the three main upgrade paths, offering insights into when each solution is most appropriate, and how our product offerings fit into those choices. Selecting the right travel gearbox today ensures your machinery remains reliable and productive, minimizing unexpected downtime and costly repairs in the future.

Option 1: On-site Repair and Rebuild — When It’s Right

For many operators, a rebuild performed on-site or in a local workshop can be the most practical solution, particularly when the gearbox is experiencing minor wear but has not failed catastrophically. Rebuilding a gearbox involves carefully disassembling the unit, inspecting every internal component, and replacing those that are worn or damaged. This process allows the operator to extend the gearbox’s service life while avoiding the higher cost of a full replacement.

Typical Signs That Rebuild Is Feasible

Identifying whether a rebuild is a viable option requires a thorough inspection of the gearbox. Some of the most common indicators include:

Oil leaks or worn seals: Minor leakage often indicates that the internal bearings and gears are still in good condition. By replacing seals and gaskets, the gearbox can continue to operate efficiently.

Noise or vibration during operation: If a gearbox produces unusual noises at specific speeds or loads, it may signal wear in bearings or specific gears. However, if these issues are limited to certain components, a rebuild can restore full functionality.

Reduced performance: Slower travel speeds, inconsistent torque, or decreased efficiency often suggest minor wear that does not require full replacement. In such cases, replacing key components through a rebuild can be highly cost-effective.

Visual inspection: Sometimes surface wear, light pitting, or slight scoring on gears can be addressed through a rebuild without impacting the long-term reliability of the unit.

A rebuild is generally not suitable if the gearbox shows extensive internal damage, broken gears, or severe deformation of the housing. Attempting a rebuild in these conditions can lead to repeated failures and increased operational risks.

Parts Typically Replaced in a Rebuild

During a rebuild, only certain components are replaced to restore the gearbox to optimal working condition. Commonly replaced parts include:

Seals and gaskets: Ensures oil retention and prevents contamination.

Bearings: Critical for smooth rotation and torque transfer.

Selective gears: Especially those with surface wear, pitting, or minor tooth damage.

O-rings and bushings: Prevent leaks and maintain alignment of moving parts.

LB provides complete rebuild kits that include all necessary components for popular travel gearbox models. Our kits are engineered to match OEM specifications, ensuring that rebuilt gearboxes deliver reliable performance and extended service life.

Advantages of On-site Rebuilds

Cost-effective: Replacing only worn parts keeps expenses lower than a full new unit.

Quick turnaround: Rebuilds can often be completed faster than waiting for a new gearbox to arrive.

Flexibility: Suitable for fleets with budget constraints or for equipment that is not in constant heavy use.

While a rebuild is a practical solution, it requires skilled technicians, proper tools, and careful inspection to ensure quality and reliability.

Option 2: Remanufactured (Reman) Units — Balance of Cost and Reliability

Remanufactured, or reman, travel gearboxes occupy a middle ground between on-site rebuilds and brand-new units. A reman unit is essentially a pre-owned gearbox that has been completely disassembled, cleaned, inspected, and restored to meet or exceed OEM standards. Components showing wear are replaced, and the gearbox is reassembled, tested, and certified for performance.

Understanding the Reman Process

The remanufacturing process is meticulous and follows strict quality control procedures:

Disassembly: The used gearbox is completely taken apart, and each component is thoroughly cleaned.

Inspection and Measurement: Bearings, gears, shafts, and housings are inspected for wear, cracks, and tolerance deviations. Components outside acceptable limits are replaced.

Component Replacement: Critical parts, including gears, bearings, seals, and bushings, are replaced with high-quality, OEM-equivalent parts.

Reassembly: The gearbox is carefully reassembled to precise tolerances, ensuring smooth operation.

Testing and Verification: Every reman unit undergoes operational testing to validate torque, speed, vibration, and noise levels, guaranteeing reliability in the field.

Benefits of Reman Units

Lower cost than new: Reman gearboxes offer significant savings while delivering performance close to a new unit.

Proven reliability: Full testing ensures the unit meets OEM performance specifications.

Reduced lead time: Reman units are often available faster than ordering a brand-new gearbox, minimizing downtime for the machine.

Environmental sustainability: Remanufacturing extends the life of existing gearboxes, reducing waste and resource consumption.

Reman units are particularly suitable for medium to high-utilization equipment that requires reliable performance without the upfront investment of a brand-new unit. LB’s reman travel gearboxes are manufactured to rigorous quality standards, providing fleets with confidence that their machinery will remain operational for years.

Option 3: New OEM-equivalent and Upgraded Gearboxes — Performance & Warranty

For machines that operate under heavy loads, continuous cycles, or in demanding environments, investing in a new OEM-equivalent or upgraded travel gearbox is often the most cost-effective solution in the long run. These gearboxes offer the highest level of performance, durability, and peace of mind.

Advantages of New Units

Advanced materials: Modern gearboxes use improved alloys and surface treatments, enhancing wear resistance and lifespan.

Tighter tolerances: Precise machining reduces noise, vibration, and heat buildup, increasing overall efficiency.

Full warranty coverage: New units are covered by manufacturer warranties, providing protection against unexpected failures.

Latest design improvements: New gearboxes incorporate engineering updates that improve torque handling, reduce weight, or increase efficiency.

Ideal Applications for New Gearboxes

Continuous, high-intensity operations such as large construction projects or mining.

Situations where downtime is extremely costly and must be minimized.

Fleets that aim to maximize machine life and minimize maintenance interventions.

LB offers a wide range of new travel gearboxes designed for heavy-duty applications. Each unit meets strict OEM-equivalent specifications and comes with a full warranty, making them a smart choice for operators who cannot compromise on performance.

Decision Checklist: Uptime Targets, Application Intensity, Long-Term Cost

Choosing the right travel gearbox upgrade requires balancing operational demands, cost, and risk. Consider these factors:

By evaluating your fleet’s utilization patterns, expected service life, and maintenance resources, you can select a solution that optimizes long-term operational efficiency and minimizes unexpected repair costs. LB’s full range of products supports all three strategies, allowing operators to make informed decisions with confidence.

How Our Product & Service Options Map to Those Choices

LB provides tailored solutions for every scenario:

Rebuild kits: Complete sets of bearings, seals, gaskets, and selective gears for on-site repairs.

Remanufactured gearboxes: Fully tested, OEM-spec, ready-to-install units for a balance of cost and reliability.

Premium new gearboxes: OEM-equivalent units with upgraded materials, precision tolerances, and full warranty coverage.

Every product is supported by technical documentation, compatibility guidance, and responsive customer support. Our range ensures that whether you choose a rebuild, reman, or new unit, you receive high-quality, reliable components built to last in the most demanding applications.

Minimizing Downtime During Swap: Logistics and Parts Planning

Downtime can be one of the highest hidden costs in heavy machinery operations. Reducing the time a machine is offline during a gearbox replacement requires careful planning:

Inventory readiness: Keep rebuild kits, reman units, or new gearboxes on hand for critical machines.

Parts cross-reference: Ensure supplementary components, like bolts, seals, and bushings, are available before starting work.

Scheduling: Plan replacement during periods of low operational demand to minimize impact on productivity.

Technical guidance: Work with a trusted supplier like LB to ensure installation instructions are clear and support is available if needed.

Proper preparation and strategic planning can cut replacement time significantly, keeping your fleet operational and reducing project delays.

Conclusion

The right approach to upgrading your travel gearbox depends on operational intensity, budget, and tolerance for downtime. Whether opting for an on-site rebuild, a remanufactured unit, or a brand-new gearbox, LB provides high-quality solutions designed to meet the demands of modern earth-moving machinery. Our range of rebuild kits, reman gearboxes, and new units ensures operators can maintain uptime, reduce long-term maintenance costs, and keep equipment performing at peak efficiency. For personalized guidance and to determine the ideal solution for your machinery, contact us today. Durable travel reducers and high-performance gearboxes from LB keep your equipment moving efficiently and reliably.

FAQ

Q1: When is a rebuild more suitable than a remanufactured gearbox?
A: Rebuilds are best for minor wear, seal issues, or partial gear damage where replacing selected components restores full function without the cost of a new unit.

Q2: How do remanufactured gearboxes compare to new units in terms of reliability?
A: Reman units are rebuilt to OEM specifications, providing reliable performance at lower cost, while new units offer enhanced materials, precision tolerances, and a full warranty for high-demand operations.

Q3: What strategies minimize downtime during a gearbox replacement?
A: Maintain inventory, cross-check parts, schedule replacements during low-use periods, and follow technical guidance from your supplier.

Q4: Are LB gearboxes compatible with most excavator models?
A: Yes, LB offers rebuild kits, reman units, and new gearboxes compatible with popular excavator and earth-moving machinery models, ensuring reliable operation.