Geek Articles

Completing the Teardown of the Sony FE 70-200 f/2.8 GM OSS: Part II

Published February 27, 2017

You probably shouldn’t read this article unless you’ve at least skimmed through Part 1. To summarize, we had a Sony FE 70-200mm f/2.8 GM OSS lens that had been dropped and no longer would focus. We tore it down both to see if we could repair it and to see what-all was up inside there. In the first part, we did the initial disassembly of the major components and a complete disassembly of the back (mount) half of the lens. We found a few surprises and some different ways of doing things. But we didn’t find the problem with the lens.

The Rest of the Teardown

So after a snack break and some more caffeine, we tackled dissecting the front half of the lens. You can see the Southern Fairy Tale ring on top, with the black plastic zoom-link ring right underneath it (you can see a metal zoom key peaking out above it on the side away from Aaron’s hand)., 2017


We start by removing the lock-on ring that connects the front half to the back half of the lens. You can see the ring of 8 screws holding the ring assembly to the front of the lens. There are 4 additional screws in the little notches, two of which are by Aaron’s forefingers., 2017


Taking all of those out let us remove the lock ring from the front half of the lens., 2017


As you might expect, only the plate is fixed to the front of the lens, the locking ring spins freely behind the plate, threading onto the rear half of the lens to attach it., 2017


There’s also a shim under the plate. This would be a spacing shim either for backfocus adjustment or for optical spacing (probably the latter)., 2017


Here’s where we found our first problem with the lens. It didn’t prevent focusing; but it may well have caused an optical issue. Remember, this lens had been dropped. We were told the drop was only about 2 feet, and there was no external evidence of damage (no scuffs, dents, etc.)

When we looked at the attachment plate above more carefully, it became apparent that two of the screw holes on one side of the lens were bent downward slightly., 2017


Two holes on the opposite side were bent upward slightly. This plate is attaching two heavy lens-halves, and it’s fairly thin aluminum (or aluminium, if you have a non-U. S. plate). The picture below shows the thickness of the plate through one of the screw holes; we measured it as 1.2mm. That might be thick enough if it was stainless steel or titanium (I’m no materials engineer) but this is aluminum; we could bend it with our hands. If the screw holes were bent, we had to assume the rim of the plate was also., 2016


Some engineer with way more math than me obviously calculated that this plate was thick enough to hold the mass of the two lens-halves together. But I’m damn sure he didn’t consider the part about force and velocity squared and all, because this plate, the one I can bend in my hands, is not going to resist much force. At all.

While the plate did hold the lens together just fine despite these bends, we’re obviously concerned that the bent plate could affect the lens optically. There are strong elements on either side of that connection and a tilt of a few microns could cause some significant optical disturbance.

Anyway, while we aren’t happy about the plate, it certainly wasn’t preventing the lens from focusing, so we continued on with our disassembly after getting the parts department to order a replacement plate.

With the connecting ring out of the way, we can access the keys to remove the inner ring linking the zoom barrel you turn to the zoom mechanism inside the lens., 2017


Removing those keys lets us take off the connecting ring and then remove the front outer fixed barrel. Like the other outer barrels, it has weather resistant rubber strips; the blue one is a seal, the black fuzzy felt one further back goes under the rotating barrel., 2017


Looking inside the outer barrel, you can see the focus-hold button mechanisms and the flexes that connect them., 2017


Underneath we start to see the inner workings of the zooming groups and front focus motor. You might think ‘look at all the cool stuff in there’. We thought, ‘oh, crap, this is going to take forever’. If you look you can see a position sensor over on the left side, the big GMR unit hanging over the ring USM motor on the right side, and flexes criss-crossing every damn where. More and more, this lens looks like it’s got a lot of Nikon heritage., 2017


Rotating around to the other side, there’s another PCB, presumably doing some position processing since it’s connected to all those position sensors., 2017


The focusing ring was the next obvious removal and with the rubber taken off there was easy access to the screws and collars holding it in place, after which it slips off of the lens., 2017


This is at least partially a fly-by-wire-focusing lens so inside the focus ring is a magnetic strip. When you turn the ring a sensor reads the strip and sends a signal to move the rear focusing elements accordingly. The front focusing elements can be controlled mechanically by the ring or through the ring USM., 2017


And now we’re getting down to the inner workings of the front half of the lens. We were pleased to see an optical adjustment collar up here, too., 2017


I’m going to compress about an hours worth of work now, trying to keep this post a reasonable length. But that set of flexes and sensors you saw 5 pictures ago was removed., 2017


After that we spent 4 or 5 minutes colorfully discussing the parentage of the lens’ mechanical designer who saw fit to make the stacking of the ring USM an integral part of the disassembly. In a nice lens, designed with the thought that someone might actually repair it some day, you take out a couple of screws and take off the ring motor assembly. In this lens we (I’m using the Royal “We” here; Aaron does all the hard stuff) have to take the USM apart piece by piece to get further into the lens.

So after carefully marking the alignment, Aaron started counting turns to remove the pressure plate (because it has to go back to exactly the same point)., 2017


After which we unstacked all of the rings and the USM motor was off., 2017


With the motor off, the next ring is a clutch or transfer ring that translates focusing movement to the focusing elements. Well they would, if they worked. We were now able to see the front focusing group didn’t want to move very well since we could turn this ring by hand now. You can see the ring rolls on very robust bearings (red line) and moves the focusing keys connected to the internal group (green line)., 2017


Once we took the keys and one locking pin out, this ring came right off. We were grateful the tensioning springs underneath it came right off with it. Sometimes those spring out like a jack-in-the-box and we have to spend 15 minutes on hands and knees searching for them., 2017


The next ring down comes right off, too. It rotates on a beautifully made bed of 30 ball bearings, which is one of the reasons this focus ring is so nice and smooth. We both did another prayer of thanks, because none of the ball bearings escaped the disassembly table and made a mad dash for freedom. Ball bearings are the escape artists of the lens prison system., 2017


Just in case any of you want to know how we keep the ball bearings from running away during disassembly, they are corralled on a Dycem non-slip pad. Dycem is one of the great accomplishments of humanity, ranking slightly below the invention of fire and the wheel, but well above the printing press in my pantheon of most important advancements., 2017


Next, we took off the front (filter) ring, which like all other joints in this lens has a nice rubber seal. Right below the top ring you can see 3 of the 6 heavy rollers that the front focusing element slides up and down on., 2017


Then we removed the front group, which is two cemented elements. This, of course, could have been done at any time during the teardown, but we were doing most of our work with the lens face down, so it seemed best to leave it until near the end., 2017


Oh, Yeah. About that Focusing Problem

At this point we we had one piece left – the front group barrel assembly you can see in the picture above. This contained some zoom elements in the smaller part of the barrel, and the front focusing group in the larger part. Reaching through the slots with forceps we could tell that the focusing group was still grinding when we moved it up and down, with a lot of resistance. We could also see it was slightly tilted. This usually means a roller or cam was broken or bent.

We removed all 6 rollers, which by the way are some really robust, ball bearing containing, pieces of engineering. They were all working fine and even with them out of place the focusing groups was still scraping when we tried to move it., 2017


Looking through the slots where the rollers had been, we could tell there was some form of spring loaded plate system with the focusing element; three of the rollers above went into the actual focusing element, three into the plate below the spring. But we couldn’t find a way to open things up further., 2017


We decided to put the lens back together, bite the bullet and see if the service center could repair it. But being a suspicious person by nature I did some checking first and found out, in typical Sony fashion, this entire assembly was considered a single part. So if we sent it in they would replace this entire assembly at a repair cost of slightly more than half the price of a new lens. Needless to say, we switched into nothing-to-lose mode and went back to looking for a way into this assembly.

We could have removed the zoom groups from the small end, but that wasn’t going to give us access to the larger focusing area. The only way in appeared to be by removing the second group, which was held in place with  both a spanner ring and also with adjustable collars through the side of the lens., 2017


Oh, and lots and lots of silicone glue. So we (royal “We” again – Aaron did this while I made more coffee) position-marked and removed the collars and chipped out lots and lots of glue., 2017


Finally we got the element out and could actually look down onto the top of the focusing element. (And yes, we realize there’s more glue to clean up before reassembly. Don’t be snarky. You’re tired just from reading about it, so you can understand we were really sick of doing it.), 2017


There’s another spanner ring down over the focusing element, so we took that out and then just about lost our minds. Because there’s another ring of beautiful ball bearings under it. We’ve never seen anything like this before and at this point really had no idea what we were seeing., 2017


Despite multiple cups of coffee and the resultant tremor, Aaron managed to get the focusing assembly out without spilling any ball bearings. (Notice how I use ‘we’ when I know everything’s going fine, and switch to ‘Aaron’ when there are 30 ball bearings that might spill onto the floor.), 2017


So we made our second ball-bearing corral. We kept them separate on principle, but they’re the same ball bearings as the other set. What size you ask? Oh, 2mm, which is just a bit thicker than that connecting plate I’m obviously not happy about., 2017


We looked at the internal focusing assembly and saw there was a pressure spring at the bottom (red arrow), pressing up against the focusing element in a cage-like arrangement. It appeared to be out of position, creating a bit of a tilt of the element that was scraping the inner barrel when the focusing group moved., 2017, 2017


We (yeah, I’m back to taking credit now) reassembled it with the spring properly positioned back under it’s little latches like it should be., 2017


I won’t bore you with reassembly, except to add that we discovered that the spanner ring over the ball-bearings is like that for a good reason. Tightening the spanner compresses this bottom spring and you can ‘dial in’ the proper amount of tension for the focusing element. Too loose and it rattles around a bit. Too tight and it gets a little resistance to sliding up and down. It’s an interesting arrangement.

But if this spring comes out of position with any regularity the repair is going to be a royal PIA. This is just one dropped lens so let’s not run screaming about what may or may not happen again. We may never see this again. Or we might. Only time, and a few more dropped lenses, will tell.

Usually I end these posts by saying we’ve got the lens reassembled and it’s back in stock now. In this case we’ll wait for a new connecting plate, and then optically test and adjust the lens after final assembly, and really, really carefully check it before putting it back in stock. But we did reassemble it with the old connection plate to make sure the autofocus system worked properly.

So What Did We Learn Today?

Well, first and foremost, that lens repair is a miserable way to make a living. And lens repair on this lens will be miserabler than most.

Second, we learned that dropping your lens is bad, so don’t do that.

Third, 1mm thick aluminum plates maybe shouldn’t be used to hold two halves of a heavy lens together. And yes, Fanboy, I know the Sony engineers are smarter than I am. They designed 962 really great parts that I couldn’t have designed. But it doesn’t take massive engineering knowledge to figure out that the thinnest piece of soft metal shouldn’t hold the two biggest pieces together.

And finally, we learned there’s some really elegant and complex engineering in the Sony FE 70-200 f/2.8 GM OSS lens. There’s also some engineering that just seems complex. It may be far more awesome than I realize and I’m just missing the point. Or not.

I’ll repeat what I say all the time: Sony is trying a lot of new things; that’s how you advance. I completely admire the risk taking and efforts to try new things when most manufacturers are just fine-tuning what already is. Some of these new things turn out to be awesome, some don’t. It’s just as important to identify which new things are not better, or not even adequate, as it is to identify when the new thing is a dramatic improvement.


Roger Cicala and Aaron Closz

March, 2017


Author: Roger Cicala

I’m Roger and I am the founder of Hailed as one of the optic nerds here, I enjoy shooting collimated light through 30X microscope objectives in my spare time. When I do take real pictures I like using something different: a Medium format, or Pentax K1, or a Sony RX1R.

Posted in Geek Articles
  • Patrick Chase

    It’s also easier to take anything apart if you don’t care about reassembly.

    That’s how engineers avoid wasting too much time when doing “competitive analysis” 🙂

  • Patrick Chase

    I think that one key difference is that people who buy serious construction equipment tend to be much more knowledgeable about what they’re getting than photographers, and they hold the manufacturers to account. Also those folks are very cognizant of service costs and turnaround times, and factor those into their purchase decisions much more than we do.

    LR is an interesting case, because their business model has forced them to develop expertise on par with that of a large construction equipment operator. They’ve also recognized that it’s mutually beneficial [*] to share what they’ve found with the rest of us, which is IMO a good step towards holding the manufacturers’ feet to the fire.

    [*] It’s beneficial for LR for two reasons: In the short term these blog posts drive eyeballs and rentals. In the longer term the actions we readers take presumably amplify their message to the manufacturers, and increase the likelihood of change.

  • Patrick Chase

    Don’t feed the trolls.

  • Patrick Chase

    I think that’s right – My recollection from when I did this professionally is that with good packaging a vulnerability like that would be a nonissue. I think that in this specific case the concern should be around operating shock.

    To put this in perspective, people ship glassware through the mail with reasonable success, provided the packaging is well designed. Nobody expects glassware to withstand the sort of handling that a lens will see, though.

  • I’m not sure about that. It does limit what I can write about, though.

  • I really thought the ball-bearing corral was a high point.

  • What he said!

  • We’d try it if they’d let us. But that would probably have to be in at least 3 parts.

  • Really? I didn’t get that impression at all. What made you think that?

  • I wouldn’t think so if it was packed decently, that kind of shock should be distributed throughout the lens. I think it would take more of a blow on one end or the other to transmit force through that plate. But that’s just me thinking, which doesn’t always work out well.

  • The first time, definitely taking apart. You don’t know where you’re going and are working on just general principles and common sense. After you’ve disassembled a given lens a few times it’s much easier.

  • We have not tried any of those.

  • Wilson, we don’t have access to that information, it’s proprietary, although we’ll eventually figure it out. Many hints make me think subassemblies are optically adjusted prior to assembly, but that’s not an option we’ll have either.
    However, the lens can usually be reassembled without most of the outer barrels, then adjusted, then fully reassembled.

  • We do not do repairs for others, I’m afraid. We can’t even keep up with our own repairs.

  • Don Farra

    Roger, thank you once again for guiding us through another adventure into the unknown. I have question for you, is it harder to take apart a lens or reassembling it?

  • Cool!

  • HomoSapienSapiens

    I can’t help but wonder if the lens was designed with that attachment plate meant to be titanium or stainless steel; but then, at the last minute, for some unknown reason but probably to meet a target cost for the lens, aluminum was used instead? In other words, maybe the fault doesn’t lie with the designer(s).

  • David Bo Hansen Cartagena

    Definetly no.

  • David Bo Hansen Cartagena

    It dosen’t make sense to design a lens to break at a certain point since it’s not a ie. Safety component designed to break at a certain point. And with all those screws on the aluminium ring and the big outer thread it’s certain they didn’t think of it as a place designed to break should the lens be dropped.

  • David Bo Hansen Cartagena

    I work with Mechanical construction i SolidWorks and also have education as an machinist and completely agree. Some parts are made very sturdy and almost overconstructed while other parts are underconstructed and too fragile. That aluminium (Yes I am from that part of the world) ring is clearly not made properly and thats obvious just by looking at it.
    My mantra is simple Mechanical design is better. This design looks like the designers did everything to make it as complex as possible.

    Thanks for showing us this design. I am now certain that I will never buy this lens since it will cost a fortune to repair should it ever need some.

  • Patrick Chase

    I think you’ve missed the point. I already said that Sony’s bodies are fantastic, but their lens lineup is deeply problematic. Switching to a different body doesn’t help with that. In fact making the specific change you suggested would only make the situation worse because the A99 II:
    1. Can only be used with Sony’s *old* A-mount lens lineup that they’re not aggressively developing any more, thus eliminating hope that things will get better in the future.
    2. Can’t be used with adapted lenses the way E-mount bodies can
    Also I like super-telephotos. The biggest lens I own is a 300/2.8, but I rent 200-400/4, 400/2.8, 500/4, 600/4 etc. lenses when needed. Sony’s A-mount telephoto lineup is an obsolete joke. They have old unstabilized 300/2.8 and 500/4 lenses that they inherited from Minolta, but nothing else.
    I also think that the a99 II is a step in the direction of a true sports camera, but isn’t there yet..

  • Brandon Dube

    Shit, if the MTF bench is sold I’m out of a job!

  • Ralph Wallace

    Roger and Aaron – It was impressive as heck to follow along (as much as any ignorant layperson ever could) while you disassembled, evaluated and re-assembled this extremely complex piece of machinery. My assembly experience consists of plastic model building (primarily Revell) military ships and planes and, later, HO guage buildings and rolling stock with careful painting, decorating (decals) and aging by hand. What you did here is another whole dimension and I was properly awed (if not shocked). Thank you for inviting us to accompany you on the journey. Hopefully your success was rewarded with copious quantities of Johnny Black (or better yet, Blue) to calm your frazzled nerves. Bravo!

  • Zaphod

    Roger, there are some products out there that screw onto the filter thread of a lens and add a rubber ‘bumper’ to it. Have you trialled these products, and do they work to reduce impact damage? (DeluxGear/easyCover/etc)

  • Wilson Laidlaw


    Do you have to check the optical properties of the two halves of the lens before reassembly for things like adjustable element spacing, adjustable collars, etc, which are only accessible with the lens disassembled? If so did you have to get from Sony what the optical properties of the two sections should be, prior to re-joining them and do you have to power up each half of the lens to do the check? I like your little sucker for lens element lifting. When I took my rather large Leica Visoflex/Televit Telyt 560mm/f5.6 head apart, a small sucker similar to that did nothing to remove the single cemented group from the barrel for cleaning. I had to use the large windscreen sucker off my auto GPS to get enough suction to pull the group out, which I suspect had not been moved since new, in the 1960’s.

  • FreedomCostsPlenty

    I wonder if that weak plate joining the halves would even experience displacement during shipping? That much mass being thrown around by UPS?

  • xslavic

    I could say from what i saw in the dissassembly pictures that this lens is designed by Sigma.

  • Paul M

    Years ago I bought my wife a Canon Ixus 700 or something. I fumbled it and dropped it all of four inches onto a table; the lens mechanism jammed and the camera simply said E18. It turned out to be a common problem with many Canon compacts at the time. I read a guide how to hold the lens feeling for the misalignment and pull it and sort of bend it, and it clicked into place.
    Anyway, my point is that some lenses are vulnerable in ways they really shouldn’t be.

  • GregoryH

    I lack faith that Nikon would do as good or careful a job as you folks. Do you do general repairs for privately owned Nikon gear?

  • Klaus Pforte

    Thank you very much for this great work of art. Very well written and imaged!
    Other people only write 140 characters to make the world crazy. You write some thousand characters more and make many readers happy.
    I will come back when you disassemble the Space Shuttle next time.
    Best regards, Klaus

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