Orminster / Thule double step repair

[Figaro]

Anyone have experience of dismantling these steps ?
I think I've a broken gear on my step so removed it for attention.
But I'm having trouble getting to the gear.
I've removed the two nuts circled in red, but nothing moved. On the other end of the bolts are a hex allen key fitting but they are very tight.
I wanted to check before forcing undone.
The other visible nut circled yellow, I didn't undo as the bolt on the other end is behind the black plastic cover.
On the other side is a square drive with an R clip. Removing this clip didn't help either.
TIA

 

[Figaro]

Bump ......

Has nobody had one of these apart for repair ?

 

[GMLS]

Have you had a good search on Youtube?

 

[Figaro]

Have you had a good search on Youtube?

Yes, not found anything relevant so far. Also searched on here as I was sure I'd read someone dismantling one for repair, but can't find it now.
I'll search again.

 

[Figaro]

Ok, got it sorted now.
In case anybody else needs to do this the process is as follows.
After removing the two nuts circled yellow above, remove the R clip and the nut and bolt on the other end of the two connecting bars between the motor drive and the step.
This will allow the motor to come off.
Remove two screws and a nut and bolt to remove the black plastic cover and two screws to remove a metal plate.
This reveals the gears.
The drive shaft and large gear can be lifter out.
The large gear wheel cog teeth on mine were a bit chewed up, but it seems only half the wheel is used in operation.
So I've turned the gear wheel around so it uses the previously unused section of the cog.
It's a bit of a gamble but all put back together and it seems to work ok.
If the repair doesn't last the gear cog wheel is available on ebay for 68.83 pounds and at least I know how it comes apart now.

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[paddymcc]

Ok, got it sorted now.
In case anybody else needs to do this the process is as follows.
After removing the two nuts circled yellow above, remove the R clip and the nut and bolt on the other end of the two connecting bars between the motor drive and the step.
This will allow the motor to come off.
Remove two screws and a nut and bolt to remove the black plastic cover and two screws to remove a metal plate.
This reveals the gears.
The drive shaft and large gear can be lifter out.
The large gear wheel cog teeth on mine were a bit chewed up, but it seems only half the wheel is used in operation.
So I've turned the gear wheel around so it uses the previously unused section of the cog.
It's a bit of a gamble but all put back together and it seems to work ok.
If the repair doesn't last the gear cog wheel is available on ebay for 68.83 pounds and at least I know how it comes apart now.

Could you get a 3D printer to make one? Certainly would be cheaper, don't know how durable it would be tho.

 

[Figaro]

Could you get a 3D printer to make one? Certainly would be cheaper, don't know how durable it would be tho.

It's an aluminium cog, do 3d printers do ali, I thought they only did plastic ?
Anyway it seems ok but if it fails again I'll just buy one now I know how it's put together.

 

[paddymcc]

It's an aluminium cog, do 3d printers do ali, I thought they only did plastic ?
Anyway it seems ok but if it fails again I'll just buy one now I know how it's put together.

Sorry, for some reason I thought that it was made of plastic . No the printers don't do Ali.