Carey, I've seen this on a Bachmann 70 tonner and and P2K SD-24. When I got them new, I opened them up, cleaned up the obvious factory sloppiness, and pulled the gears to check them for being true and for burrs. Surprisingly, both locomotives had small burrs on the gears and filing them down got the gears to mesh more closely. I put a small amount of LaBelle #106 grease in the gear boxes and closed them back up.
In the last two months, I've had to open both locomotives back up for other problems. In both gear boxes, the grease, instead of being sort of semi-liquid like I'm used to, was dry and had rolled up in tiny balls between the gears. Running them without the shell, I could see the grease kind of bouncing around in the gear box. I cleaned out the gear boxes and replaced the grease with a about two drops of ATF. My unscientific guess is that both engine ran about 10% quieter and smoother. Since I use a tiny amount, I haven't seen any signs of it being flung outside the gear box. Don't know if I'm not doing something right or unlucky, but I've now seen this in two locomotives. I've got a bunch of engines coming up for annual maintenance so I'll see if the grease problem repeats itself. I did buy the grease new but I suppose it's also possible I got a bad batch.
In the last two months, I've had to open both locomotives back up for other problems. In both gear boxes, the grease, instead of being sort of semi-liquid like I'm used to, was dry and had rolled up in tiny balls between the gears. Running them without the shell, I could see the grease kind of bouncing around in the gear box. I cleaned out the gear boxes and replaced the grease with a about two drops of ATF. My unscientific guess is that both engine ran about 10% quieter and smoother. Since I use a tiny amount, I haven't seen any signs of it being flung outside the gear box. Don't know if I'm not doing something right or unlucky, but I've now seen this in two locomotives. I've got a bunch of engines coming up for annual maintenance so I'll see if the grease problem repeats itself. I did buy the grease new but I suppose it's also possible I got a bad batch.