Only one of the gears has a tooth damaged. This gear is one of the large metal gears (about the fourth reduction starting at the motor helical drive shaft gear) The gear pitch diameter is about 2 1/4 in od x .375 in face. This is the one with the hex head drive shaft. Is there a place where I can obtain a replacement part?
The original unit must have been a misbuild because the origin of the problem was one of the four screws that secure the drive motor had come out and jammed in the gear that is damaged. Screw appears to be a #10-32 x 3/4 in long. Unit now works but clunks as it cycles past the damaged tooth. It will damage other gears if this continues.
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This Shredder is an Aurora AS650C Rebranded for Walmart as Durabrand. You can call Aurora at 800-327-8508 8-5 PST and tell them that you need one of the plastic gears for the WM6X Durabrand, they know exactly what your talking about, and will offer you two gears. The one that is in contact with the drive motor is gear "A" and the Plastc reduction gear that drives the steel gears is gear "B" Hope this helps
I suggest using Belzona (metal compound). Mix it with its hardner, paste it over the broken gear (dont worry if it gets over a couple of other gears. Let Belzona sink and dry (4-5hours). Get a Dremel drill with a fine blade on it and cut accurately where the teeth are meant to be. Voila, you have fixed your gear.
Drill 3 or 4 holes along the path of where each gear tooth is missing. The holes should be sized to about 75% of the width of the tooth at its base. Drive appropriate sized screws into the holes. Clip off the tops of the screws to match the original tooth height. File the sides of the screws at an angle to match the original tooth sides. You are essentially replacing the missing gear tooth with three or four screws filed to match the tooth profile.
Only solution - Don't buy a FELLOWES shredder.
It is ludicrous that they cannot (will not) supply a spare gear wheel when there are thousands of instances of them failing. Or even think outside the box - fit metal ones?