May 27, 2025
Ball screws are the lifeblood of motion control systems in countless industries—from CNC machining to aerospace engineering. But like all mechanical components, even the most precisely manufactured ball screws will eventually show signs of wear. Knowing whether to repair, rebuild, or fully replace a ball screw can save time, money, and unnecessary downtime.
In this post, we’ll walk you through the warning signs to look for, the pros and cons of repair vs. replacement, and what makes Express Ball Screw Repair & Engineering a trusted choice for keeping your equipment in peak condition.
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A ball screw is a mechanical linear actuator that converts rotational motion into precise linear movement using a ball bearing mechanism. It’s designed for efficiency, accuracy, and repeatability. However, constant use—especially in demanding environments—introduces wear on the screw shaft, ball nut, and bearings.
Common sources of wear include:
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Here are the most common indicators that your ball screw system may be due for repair or replacement:
Backlash (the loss of motion due to gaps in mechanical components) is often the first warning sign. If you’re experiencing decreased positional accuracy or slop in the system, it may be due to ball nut wear or bearing fatigue.
Unusual grinding, squealing, or clicking sounds during movement often point to internal damage, loss of lubrication, or bearing degradation.
A ball screw that can’t handle the same loads as before—or binds at certain points in the stroke—might be suffering from shaft scoring, misalignment, or contamination inside the nut.
Cracks, dents, pitting, or rust are major red flags. Even superficial corrosion can lead to deeper failure under high loads.
Overheating during normal operation can indicate increased friction, often due to wear or contamination.
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The decision between repairing and replacing depends on several key factors:
Cost:
Repair or rebuild is often significantly more affordable—typically 30% to 60% less than purchasing a brand-new unit. This makes it a strong option for companies looking to reduce maintenance expenses without sacrificing performance.
Turnaround Time:
If the unit is repairable and we have compatible parts or cores in stock, the repair process is often faster than ordering a new ball screw, which may involve longer lead times due to manufacturing or shipping delays.
Condition of the Ball Screw:
Repair is a great option when the ball screw has localized wear, minor surface damage, or degraded components, but the shaft and overall structure are still intact. However, if the shaft is cracked, bent, or the thread form is excessively worn, replacement is usually the only viable solution.
Performance Expectations:
A professional rebuild can restore your ball screw to OEM-level performance, often matching the precision of a new unit. Replacement, however, guarantees "like-new" specifications and is ideal for mission-critical applications that demand the highest possible accuracy.
Customization and Compatibility:
Repair allows you to maintain your existing configuration, which can be important if you're working with legacy machinery. On the other hand, a replacement offers the opportunity to upgrade or modify the design to meet evolving system requirements.
If your unit has localized wear or damage but the screw shaft is intact, repair or rebuild is usually the smarter route. At Express, we disassemble, clean, inspect, and replace worn components, restoring the assembly to OEM or better standards.
However, if the shaft is bent, cracked, or the thread form is severely worn, a full replacement may be the only safe and effective option.
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With decades of hands-on experience and precision tooling, we offer:
Whether you're maintaining older legacy machinery or outfitting new equipment, we can help you make the most cost-effective and performance-driven decision.
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One of the biggest mistakes we see is waiting until the machine goes down before taking action. Regular inspections, paired with an understanding of the signs listed above, can help you catch issues early—before they lead to catastrophic failures.
If you're unsure whether your ball screw can be saved, reach out. We’ll inspect the unit and provide a clear, honest recommendation on whether repair, rebuild, or replacement makes the most sense.
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We now offer a selection of refurbished and new ball screws and components in our online shop—fully rebuilt and ready to ship.
➡️ Shop Now ❯
Have questions? Contact our team anytime—we’re here to help you stay up and running.
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Tags: ball screw repair, CNC maintenance, linear motion systems, machine accuracy, industrial equipment
