Once dubbed the most troubled subway cars ever, the R46s defined an era.
In short: Built by Pullman Standard in the 1970s, the R46 subway cars were once the largest single order in United States railroad history. Plagued by structural cracks and mechanical failures shortly after launch, these 75-foot giants survived a massive overhaul to become a long-standing, if controversial, fixture of New York City transit.
The R46 fleet, originally ordered as 754 individual cars, arrived in New York City amidst significant delays and manufacturing woes. While the first cars entered service on July 14, 1975, the full delivery was not completed until 1978, three years behind the initial schedule. The cars were designed with modern features for the time, including air-conditioning and air springs intended to provide a smoother ride than the heavy metal springs of their predecessors. However, the fleet quickly earned a reputation for being the most troubled cars ever purchased due to severe structural issues.
By 1978, inspectors had discovered cracks in 264 of the R46 trucks, a number that ballooned to 1,700 by March 1980. These defects were so pervasive that the New York City Transit Authority was forced to implement rigorous inspection schedules, checking the cars multiple times per week. The situation became a legal battleground, with the transit authority filing an $80 million charge against Pullman Standard and various subcontractors after discovering additional flaws, including problematic hand brake assemblies and deteriorating steel joints.
The fleet's fortunes shifted in the early 1990s when Morrison–Knudsen performed a comprehensive General Overhaul Program on the remaining 752 cars. This effort replaced the unreliable WABCO braking systems and removed the distinctive blue side stripes, giving the cars a sleek, unpainted stainless steel appearance. This overhaul successfully transformed the R46 from a mechanical liability into a reliable workhorse. Despite their rocky start, the R46s have remained in service for over five decades, serving as the oldest active subway cars in the system since January 2022. As the R211 fleet continues to arrive, the R46s are now being phased out, with retirement expected by the late 2020s.
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- Summary by Intellect · source: R46 (New York City Subway car)
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