Dewalt Dwe305 Gear Assembly Replacement Repair Guide

Difficulty

Moderate

Steps

Time Required

                          30 - 40 minutes

Sections

Trigger Assembly
7 steps
Reciprocating Shaft
9 steps
Gear Assembly
1 step

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Introduction

What you need

Step 1

              Trigger Assembly

Remove the seven 3/4" Button Head Torx Security screws out of the handle with the Torx T20H bit and IFixit Precision Bit Driver.

Remove the seven 3/4" Button Head Torx Security screws out of the handle with the Torx T20H bit and IFixit Precision Bit Driver.

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Step 2

Take the top cover off after the screws have been removed to access the trigger assembly.

Take the top cover off after the screws have been removed to access the trigger assembly.

Step 3

Remove the single 3/4" Button Head Torx Security screw that is securing the trigger assembly using the Torx T15H bit.
Pull the entire trigger assembly from the handle.

Remove the single 3/4" Button Head Torx Security screw that is securing the trigger assembly using the Torx T15H bit.

Pull the entire trigger assembly from the handle.

Step 4

Use the pointed end of the metal sludger to pry open the rectangular casing that houses the electrical contacts and wiring of the trigger assembly.
Be very careful not to damage any of the wiring or electrical contacts with the metal spudger
Assess the condition of the assembly by checking the inside of the casing for any dust, dirt, or misalignment.

Use the pointed end of the metal sludger to pry open the rectangular casing that houses the electrical contacts and wiring of the trigger assembly.

Be very careful not to damage any of the wiring or electrical contacts with the metal spudger

Assess the condition of the assembly by checking the inside of the casing for any dust, dirt, or misalignment.

Step 5

Look on the back of the assembly by turning it over to the casing where the wires protrude and see if there is any damage to the cables which are connected to the motor assembly.

Look on the back of the assembly by turning it over to the casing where the wires protrude and see if there is any damage to the cables which are connected to the motor assembly.

Step 6

Look over the spring component and see if it is misaligned or warped.
You may have to use the flat, blunt part of the metal spudger to move the spring around and see the inside of the casing.

Look over the spring component and see if it is misaligned or warped.

You may have to use the flat, blunt part of the metal spudger to move the spring around and see the inside of the casing.

Step 7

If any part of the trigger assembly such as electrical contacts, wiring, or the spring is damaged beyond repair, then replace the assembly and reconnect the new component to the wiring attached from the motor assembly.

If any part of the trigger assembly such as electrical contacts, wiring, or the spring is damaged beyond repair, then replace the assembly and reconnect the new component to the wiring attached from the motor assembly.

Step 8

              Reciprocating Shaft

Use a #2 Phillips Screwdriver to remove the large black screw at the shoe of the device or the black plastic housing.

Use a #2 Phillips Screwdriver to remove the large black screw at the shoe of the device or the black plastic housing.

Step 9

Use a Torx T20H bit and the iFixit Precision Bit Driver to remove the four 3/4" Button Head Torx Security screws from inside the shoe housing.

Use a Torx T20H bit and the iFixit Precision Bit Driver to remove the four 3/4" Button Head Torx Security screws from inside the shoe housing.

Step 10

Once the four safety housing bolts are removed, pull the black plastic cover (the shoe) from the device.

Once the four safety housing bolts are removed, pull the black plastic cover (the shoe) from the device.

Step 11

Slide the black rubber component (the boot) off to access the reciprocating shaft assembly and metal plate.

Slide the black rubber component (the boot) off to access the reciprocating shaft assembly and metal plate.

Step 12

Remove the four 1.5” Stainless Steel Button Head Torx screws that are attached to the gold metal plate. Remove the screws using a Torx T25H bit with the iFixit Precision Bit Driver.

Remove the four 1.5” Stainless Steel Button Head Torx screws that are attached to the gold metal plate. Remove the screws using a Torx T25H bit with the iFixit Precision Bit Driver.

Step 13

Remove the two smaller black ¾” Button Head Torx Screws using the Torx T20H bit with the iFixit Precision Bit Driver.

Remove the two smaller black ¾” Button Head Torx Screws using the Torx T20H bit with the iFixit Precision Bit Driver.

Step 14

Remove the gold metal plate carefully. You may need to use a flat tool to pry the cover off from the sticky surface.

Remove the gold metal plate carefully. You may need to use a flat tool to pry the cover off from the sticky surface.

Step 15

After removing the plate, the reciprocating shaft is now exposed. Remove the shaft and assess it for damages or loss of lubrication.
If the shaft is not lubricated, apply saw lubricant generously.

After removing the plate, the reciprocating shaft is now exposed. Remove the shaft and assess it for damages or loss of lubrication.

If the shaft is not lubricated, apply saw lubricant generously.

Step 16

Assess the front of the shaft where the blade goes. If dust or dirt are clogging the shaft, carefully clean the shaft with small cotton swabs and cleaning fluid.
Be aware of the blade if it is attached and take caution not to make the surface too slippery with lubricant or cleaning fluid.
If any part on the reciprocating shaft is damaged, then replace the reciprocating shaft with a new part.

Assess the front of the shaft where the blade goes. If dust or dirt are clogging the shaft, carefully clean the shaft with small cotton swabs and cleaning fluid.

Be aware of the blade if it is attached and take caution not to make the surface too slippery with lubricant or cleaning fluid.

If any part on the reciprocating shaft is damaged, then replace the reciprocating shaft with a new part.

Step 17

              Gear Assembly

Remove the heavy, grey metal cover that is located above the gear to access the assembly. Put aside the metal cover and carefully lift gear assembly out.
Evaluate the gear to ensure that no dirt or debris is jamming the gear assembly. Be sure to also evaluate the teeth of the gear, making sure no teeth have broken. Clean the gear assembly and replace gear as required.

Remove the heavy, grey metal cover that is located above the gear to access the assembly. Put aside the metal cover and carefully lift gear assembly out.

Evaluate the gear to ensure that no dirt or debris is jamming the gear assembly. Be sure to also evaluate the teeth of the gear, making sure no teeth have broken. Clean the gear assembly and replace gear as required.

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

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Author

                                      with 2 other contributors

                    Morgan Dudley

Member since: 09/04/2019

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Team

                       Embry-Riddle Aeronautical University, Team S23-G4, McClure Fall 2019                        

                                                  Member of Embry-Riddle Aeronautical University, Team S23-G4, McClure Fall 2019 



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