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How to Replace Align DS510 Servo Gears

Align model helicopters are battery powered, but the majority of the moving parts use mechanical drives and gears. The servo is a gear box that transfers power generated by the batteries into mechanical power with a series of gears. These gears rotate the propeller. The Align DS510 Servo has four plastic gears and one metal. Over time, these gears wear out because the teeth break or the tongue and groove system of the axle and gear connection fails. If the servo functions but the propeller does not spin, typically this means the gears need to be replaced.

Things You'll Need

Phillips-head screwdriver
1/16-inch screwdriver
DS510 Servo replacement gears

Instructions

- 1
  Remove the four screws at the base of the Align DS510 Servo. Unthread them with a Phillips-head screwdriver. Remove the cover of the servo by pulling it off the base. Use your thumb to force the axle of the primary gear down while pulling on the cover if necessary.
- 2
  Rotate the servo until the primary gear -- the gear around the axle that protruded from the cover of the servo -- is on your left and the three other gears are lined up to your right. From your left, count three axles over and remove the gear by placing a 1/16-inch screwdriver under it and forcing it up.
- 3
  Remove the gear farthest to the right using the same method. Remove the gear second to the left; then return to the gear third from the left and remove the second gear on the axle -- this is the only axle with two gears. Remove the primary gear on the left. As you remove the gears, place them on the table in the correct order from right to left.
- 4
  Replace the gears. First, place the corresponding gears from the replacement package on the table next to the gears you removed. Slide the primary gear over the axle on the servo farthest to the left. Next, slide the appropriate gear over the axle second to the right, then the correct gear over the axle next to the primary, and finally, replace the last gear, the one farthest to the right.
- 5
  Replace the cover by sliding the hole in it over the axle of the primary axle. Align the tongue of the base with the groove of the cover. Thread the base screws back into place.

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