How to replace the belts on a Sony TC-WR535 Dual Cassette Deck

Picture of How to replace the belts on a Sony TC-WR535 Dual Cassette Deck
If you own a TC-WR535 which cassette decks won't open anymore, it's probably because the belts of the motor are in bad shape. I'm now gonna show you how to replace them.
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Step 1: Tools you will need

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These are the tools you will need:
a container for the screws so you don't lose them
replacement belts (2 for each deck, so a whole replacement set contains 4 belts, 2 small ones and 2 larger ones)

Step 2: Unscrew Part 1

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Unscrew the 5 screws shown on the picture

Step 3: Unscrew Part 2

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Unscrew the 5 screws on the bottom of the WR535

Step 4: Inside the TC-WR535

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Now remove top part of the case and you'll see the guts of your cassette deck.
Remove the four flat cables (one on each deck, one small and one big in the middle)

Step 5: Pull off the front

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Now gently pull of the front

Step 6: The belts

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These are the two belts we want to replace

Step 7: Unscrew the 2 tiny screws

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Unscrew the 2 tiny screws on the deck on which you like to replace the belts

Step 8: Final Step

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Now remove the top part of the deck, replace the belts and then reassemble.
redeyeloon made it!9 months ago

Thanks for this great instructable. Totally nailed it on my first try. Thanks, Doug, for the hint about the plastic posts!

Very nice, clear instructable - thanks! My google search for a solution to this problem turned up your fix, and it was the first time I had heard of the instructables site. FYI, I performed this fix on a Sony TC-WE835S cassette deck, which is a dual cassette deck with very similar construction to the TC-WR535. I haven't yet obtained a replacement belt set for this deck, so I just replaced the main belt (on both transports) with a rubber band of similar size. I did not replace the smaller belt. This is a temporary fix, obviously, but it does solve the problems of cassettes not playing and becoming stuck in the machine.

I would add one step to clarify the installation of the main belt. One of the more tedious steps is getting the main (larger) belt around both main pulleys while at the same time juggling both halves of the transport to get them close enough together to wrap the belt around the motor pulley. I discovered that there are two small plastic posts on the bottom half of the transport, near the motor pulley's position (when the transport is assembled). I found it to be a big help to position the belt around these two posts, after getting it around the two main pulleys. It's much simpler then to get the two transport halves close together and transfer the belt from these two posts to the motor pulley.  I'll betcha that Sony put those two posts there for this very reason.

Hope this additional information helps those who are performing this repair.

Nice heads up on the additional positioning posts for installing the belts.
I did this repair on a Sony TD-WR645S Dual Cassette Deck, very similar. Very clear instructions. Great help. On each of the decks, there are 3 tiny screws, rather than 2 that need to be removed. I also discovered the plastic posts that Doug Brunelle mentions in previous post. I had ordered the replacement belts from 2 different sources, found by searching for them. Straight forward repair and it is back to working like new. I replaced both the large and small belts, one each on each of the dual decks. The old belts had simply aged and tired out.
dennyls5 years ago
Hi, I did this, but now the autostop/autoreverse is not working, and the tape decks only play in one direction. What did i do wrong?>?
weird_monkey (author)  dennyls5 years ago
Did you replace both belts per deck? Or perhaps the motor is slipping somewhere (I hope you know what I mean, perhaps the belt is too slippery somewhere and therefore doesn't stop) You checked all the connections (especially the 4 flat cables?
Do you know where you bought the belt kit?
Thanks Bob
weird_monkey (author)  checkin13 years ago
i bought them on ebay right here:
nice contact, shipping worked out pretty well! :)
I did buy them on e-bay, but don't see them there. Here is a link to something I found on Google that claims they have the belts. I have never done business with this company, so you are on your own.

Good Luck
I'm pretty sure I found them on e-bay--but that was quite awhile ago.
majadero4 years ago
I followed the steps and it was easy, thanks!
Do you know where you bought the belt kit? Thanks, Robert
LarryKing4 years ago
My wide belt was stretched out, replaced it with a #64 rubber band. So far so good. Deck is fully functional for the time being.
mbb704 years ago

I'm glad to have found this instruction set. Very handy, thanks.

I'd like to add one thing...

- On my unit (SN 8830563, ~1993), there is one more screw to unfasten in the dead center of the circuit board. The pieces separate nicely once this one is removed.

Thanks again!