Lionel 6466W whistle tender issues

Hello! So I got a 6466W tender from eBay, replaced the brushes, cleaned it very well and got myself a KW transformer. Toot-toot it was working great. Then my track started shorting out, but I was finding the screw from the tender shell was falling out and that seemed to be the cause. I had a 6466T and just swapped shells and the screws stayed in, but the track continued shorting. The engine worked fine without the tender. Add the tender and it would maybe make it around again and would short. it would still whistle when whistle button pressed.

AI had me move the relay arm, but with the shell off I could see where the pickup rollers wire were soldered to the interior coil lug, wires were sticking out. When I unsoldered, it seemed when they rewired, they left old wires in the solder. I rewired and soldered those wires as well as two other old cloth wires (just not the two wires that came out of coils).

It was going around the track a few times, I hit the whistle button, nothing happened, the arms didn’t move and it wasn’t clicking. I moved the relay arms, now it’s shorting as soon as I put it on the track again.

I’m super frustrated and have spent hours on this thing. I don’t understand why it stopped working in the first place. Any ideas? Thank you in advance!

I have a 6020W, which appears to be identical to the 6466W. I would check the center rail pickup rollers, and see if the top of the rivet is hitting the truck frame, this has been a problem for some of my other Lionel rolling stock. If it is touching, place some electrical tape on the underside of the truck frame. The previous owner on my 6020W also placed multiple layers of electical tape under the relay, I would try that too, if that isnt the problem it would still prevent it from becoming one in the future.

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Thank you so much! I will try that in the morning! I did put some masking tape underneath, but maybe not on the correct places (and not electric tape). Will check!!

Thank you again! I had ordered a diode to replace the rectifier on my KW transformer and it came this morning, changed it and the engines are faster, but same problem. Took your advice on the electrical tape and…

IT WORKED!! TOOT-TOOT!! Thank you so much for the advice!! :blush:

Glad I could help!

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