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This guide will show you how to replace the gearcase assembly on the Dewalt DW511 Hammer Drill. The gearcase is responsible for the translation of motion between the motor and the spinning bit, controlling the speed and torque of the motion. The gearcase is attached to the armature, so the entire assembly will need to be removed as one piece.
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Remove three 19 mm T20 Torx screws from the back of the drill.
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Place an opening tool in the groove line of the handle and pop the back loose.
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Grab the drill with two hands and pull the cover off.
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Firmly grab the body of the trigger.
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Slowly pull the trigger until the entire body is out and only attached by wires.
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With sharp point tweezers, push the little metal flap up in the hole holding the wire.
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Clamp the wire with blunt tweezers, and slowly pull the wire out.
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With a pair of blunt nose tweezers, grab the white wire.
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Carefully wiggle the wire loose.
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Pull the wire slowly until it comes out.
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With both wires free, the power cord is free from the trigger body.
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Use an opening tool to lift up the spring holding down the brush.
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Remove the brush from its holding.
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With a pair of blunt nose tweezers, grab the red wire.
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Carefully wiggle the wire loose.
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Pull the wire slowly until it comes out.
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Remove two 45 mm T20 Torx screws.
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Remove one 30 mm T20 Torx screw.
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Pull off the top case and set it aside.
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Grab the gear case cover and gently pull it out just enough to where it exposes the lever assembly.
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The lever assembly can now be lifted out.
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With the old lever assembly removed you can now replace it with a new one.
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Hold the hammer drill tool firmly by the handle.
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Gently separate the gear case unit from the hammer drill body.
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To reassemble your device, follow these instructions in reverse order.
To reassemble your device, follow these instructions in reverse order.
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CMCSC-EGGLESTON-F20S3G19
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