Dewalt Dw511 Hammer Drill Gearcase Replacement Repair Guide

Difficulty

Moderate

Steps

14

Time Required

                          35 - 50 minutes            

Sections

5

• Back Cover
• 2 steps
• Power Cord
• 4 steps
• Brushes
• 2 steps
• Lever Assembly
• 4 steps
• Gearcase
• 2 steps

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Introduction

What you need

Step 1

              Back Cover               

• Remove three 19 mm T20 Torx screws from the back of the drill.

Remove three 19 mm T20 Torx screws from the back of the drill.

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Step 2

• Place an opening tool in the groove line of the handle and pop the back loose.
• Grab the drill with two hands and pull the cover off.

Place an opening tool in the groove line of the handle and pop the back loose.

Grab the drill with two hands and pull the cover off.

Step 3

              Power Cord               

• Firmly grab the body of the trigger.
• Slowly pull the trigger until the entire body is out and only attached by wires.

Firmly grab the body of the trigger.

Slowly pull the trigger until the entire body is out and only attached by wires.

Step 4

• With sharp point tweezers, push the little metal flap up in the hole holding the wire.
• Clamp the wire with blunt tweezers, and slowly pull the wire out.

With sharp point tweezers, push the little metal flap up in the hole holding the wire.

Clamp the wire with blunt tweezers, and slowly pull the wire out.

Step 5

• With a pair of blunt nose tweezers, grab the white wire.
• Carefully wiggle the wire loose.
• Pull the wire slowly until it comes out.

With a pair of blunt nose tweezers, grab the white wire.

Carefully wiggle the wire loose.

Pull the wire slowly until it comes out.

Step 6

• With both wires free, the power cord is free from the trigger body.

With both wires free, the power cord is free from the trigger body.

Step 7

              Brushes               

• Use an opening tool to lift up the spring holding down the brush.
• Remove the brush from its holding.

Use an opening tool to lift up the spring holding down the brush.

Remove the brush from its holding.

Step 8

• With a pair of blunt nose tweezers, grab the red wire.
• Carefully wiggle the wire loose.
• Pull the wire slowly until it comes out.

With a pair of blunt nose tweezers, grab the red wire.

Step 9

              Lever Assembly               

• Remove two 45 mm T20 Torx screws.
• Remove one 30 mm T20 Torx screw.

Remove two 45 mm T20 Torx screws.

Remove one 30 mm T20 Torx screw.

Step 10

• Pull off the top case and set it aside.

Pull off the top case and set it aside.

Step 11

• Grab the gear case cover and gently pull it out just enough to where it exposes the lever assembly.
• It is important that the brushes are removed before you do this step or you may damage your brushes.
• The lever assembly can now be lifted out.

Grab the gear case cover and gently pull it out just enough to where it exposes the lever assembly.

It is important that the brushes are removed before you do this step or you may damage your brushes.

The lever assembly can now be lifted out.

Step 12

• With the old lever assembly removed you can now replace it with a new one.

With the old lever assembly removed you can now replace it with a new one.

Step 13

              Gearcase               

• Hold the hammer drill tool firmly by the handle.
• Gently separate the gear case unit from the hammer drill body.

Hold the hammer drill tool firmly by the handle.

Gently separate the gear case unit from the hammer drill body.

Step 14

• The metallic alloy gear case is attached to the armature and removes as a unit. Separation of the gear case from the armature requires specialized hand tools.
• The third photo shows a gear behind the chuck that interlocks to the gear case.
• The plastic housing is prone to damage if excessive force is applied during the removal of the gear.

The metallic alloy gear case is attached to the armature and removes as a unit. Separation of the gear case from the armature requires specialized hand tools.

The third photo shows a gear behind the chuck that interlocks to the gear case.

The plastic housing is prone to damage if excessive force is applied during the removal of the gear.

To reassemble your device, follow these instructions in reverse order.

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Author

                                      with 1 other contributor 

                    Andrew Grayson Crawford                     

Member since: 10/01/2020

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Team

                       The Citadel Military College of South Carolina, Team S3-G19, Eggleston Fall 2020                        

                                                  Member of The Citadel Military College of South Carolina, Team S3-G19, Eggleston Fall 2020 



                    CMCSC-EGGLESTON-F20S3G19                     


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                                            3 Guides authored