I was able to get a short run of replacement gears manufactured for the Magnavox D8443 boombox cassette mechanism. This is to replace one of the gears known to break on its own.

I've used a remanufactured gear of the same design and material without any problems. Now you'll be able to get your D8443 fixed! As mentioned in the auction, you might need to modify the center hole slightly using a drill bit and electric drill to make it work in your boombox.

I posted an eBay auction to handle the sale should you want/need to purchase a replacement gear. They are priced at $11.99 each with free shipping to anywhere in the continental United States.

http://cgi.ebay.com/ws/eBayISA...mp;item=230965597996

Will you post to Europe too?

I modified the auction to allow international shipping. However, actual shipping costs will be added for international destinations.

Hi, I need a couple of gears for a Philips D8644 if anyone got some spare. they about 2 cm and 2mm across,one slightly larger than the other but around these measurements.

I just posted a video on YouTube which documents the replacement of the broken cassette gear.

It's far from production quality as it's been assembled from several videos I made when narrating the disassembly procedure (just in case I WANTED to make a video someday). But it should explain the process enough for anyone who's not afraid to poke a screwdriver at their D8443.

http://youtu.be/p4YuYZVYIX8

Thanks!
Jeff

Hi Jeff, received the gears yesterday! Looking real good! Going to build them in this week, I think they are gonna work great!...

Just watched your you tube video and it the same tape cassette module,if that's what they called, as the Philips D8644 tape gear set up.Thanks for this,ill need it for when I get the gears I ordered from you,job well done..

Thanks!

I know the auction mentioned that you may need to bore out the hole a little more, by slightly wiggling around a 5/64 (or 2mm) drill bit in the existing hole, in order to fit it on your gear pin. Let me know if you needed to do that and if the process was easy enough to perform.

I hope the video explained the process well enough. There were some camera angles I wasn't able to get, especially where the wire spring is concerned, but observing where things are before removing them should more than suffice when putting it all back together.

Hi Jeff, the box is playing its 5th tape with the new gear now!... I didn't have to drill at all. Just pushed the capstan thru and turned it by hand for about 5 min.... I used Teflon grease between the shaft and gear when mounting it. Everything runs smooth... 

I did make the following modification: grinded about 2 mm of the top of the small spur gear. This made the groove on the shaft to become visible. Now it's possible to mount a clip on the shaft to keep the gear down. In my case the gear was pushed upwards against the gear above it and this made some mechanical noise.... 

Thanks for the great news! Another D8443 in full working order!

I didn't discover until I made my video that the capstan shaft is a suitable diameter. Although I hoped that the existing hole would have been the correct size, I like your "tool free" method of enlarging it. Very resourceful!

I might take a look at my gear and consider grinding a bit off the top. I modeled the new gear off of the original, but I had no clip on the gear shaft when I got my D8443, so I had no reference to how it was mounted. It just sort of stays there for me. Does it normally use a tiny 'E-clip'?

And yes, Teflon grease would be useful on the gear shaft. I find many people have their own preferences for lubricating moving parts, so I didn't directly address the topic.

Hopefully other people will be able to make use of your modification techniques. I will consider modifying the gear design when getting new ones made in the future.

Thanks!

If you look into the original gear, you will notice there is a thin ridge that fits into the groove in the shaft... This holds the gear down... A really cheap but smart system, but hey, it's Philips... Same fixation system is applied with the rev/fwd gears....

Did already 10 tapes by now! Including a C120!...