What I don't do

The noise-suppression methods below are what I HAVEN'T tried with Athearns:

-replacing the motor
-replacing the gears
-replacing the wheels
-dabbing toothpaste in the gears

Of all the above, I've only done a motor transplant once (with minimal results) and haven't tried anything else.

What I do

My remedy consists of two steps:

1. I remove the springs and brushes from the motor.  I stretch the springs slightly, then insert them back into the motor--without the brushes.

The springs are stretched so they're fractionally longer than the hole.  Stretching them too long will cause them to wear out quickly and foul the commutator.

2. All my models use WD40 as a lubricant.  I dab some on the driveshaft joints and on the worm gear with a small brush (I store a small amount of WD40 in a jar) and let it circulate through all the gears by running the engine.  I suppose other lubricants would work, but WD40 is what I've used because it's cheap and readily available.

Results

Removing the carbon brushes gets rid of the "buzzy" sound of the Athearn motor, while providing a cleaner contact that allows better slow-speed control.  However, reliability is affected.  The springs will eventually wear out and need replacement (I make new ones from wire wrapped around a 2 1/2"  finishing nail).  They usually last for over a year of light to moderate use.

Adding WD40 to the drive system works wonders with no negative long-term affects that I've found.  It takes a few weeks of running before the effects are realized.

The most rewarding result, however, is having the Athearn models--with no additional parts or cost--being mistaken for Atlas or Kato units by visitors.

Michael Eby 2006