Thrustmaster TMX/T150 gear & timing wheel replacement (two-piece model)
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The white gear inside my Thrustmaster TMX wheel stripped a few teeth. So I created this.
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Introduction
The weak link in the less expensive Thrustmaster steering wheels is the plastic gear and optical timing wheel. Over time it can wear out and with enough force, it can strip teeth. I was inspired by the Thingiverse models noted below but designed from scratch to include the timing wheel and main gear in one piece and the spur gear as a separate piece to simplify printing and minimize the need for supports. I also optimized the gear profile for durability.
Print settings
Scaling the small gear to somewhere between 99.5-100.5% may help fitment if your printer is not fully dialed in.
PLA / PLA+ (PETG and ABS not recommended but may work)
0.4mm or smaller nozzle
50% or lower fan speed - critical for the timing wheel fingers
0.2mm or less layer height
3 perimeters for 0.4mm nozzle - more for smaller nozzles such that perimeter is at least 1.2mm thick
50% gyroid infill
auto supports (snug or organic style) is OK for larger gear to support the central hole
Post-processing
no matter how well your printer is tuned, there will likely be tiny filament strings between the fingers of the timing wheel which will affect the optical sensor. You'll have to slice through these strings with a hot razor blade very carefully. If you knock down a finger, you'll have to re-print since accurate timing will be ruined! Gluing a finger back in place is extremely difficult. Do NOT aim hot air at the timing wheel fingers in the hopes the strings will whisp away - instead, the fingers will flop over ruining the print
If the larger gear is too tight on the shaft, you can use a drill bit to ream it out or aim hot air through it for a few seconds to soften it.
superglue the small gear into the larger one; clamp the gears together while the glue dries
Install guide - including a $10 ball-bearing roller upgrade
Use this video as a rough teardown/install guide. I highly recommend upgrading the belt tensioner rollers while you have everything apart. You'll need six [3mm x 8mm x 4mm] or six [3mm x 9mm x 4mm] bearings.