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Ridgid GEN5X R8642 Gear Assembly Replacement

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This guide is to help users replace the gear assembly for the Ridgid GEN5X R8642 saw. For this guide you will need: a spudger, a T20 Torx Screwdriver, a Phillips screwdriver size J1, replacement gear assembly for Ridgid GEN5X R8642, and a good attitude.


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  1. Ridgid GEN5X R8642 Gear Assembly Replacement, Gear Assembly: crwdns2935265:01crwdnd2935265:01crwdnd2935265:01crwdne2935265:0

    • Remove the plastic tab holding the handle cover in place by prying upward with the spudger until the tab pops off.

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  2. Ridgid GEN5X R8642 Gear Assembly Replacement: crwdns2935265:02crwdnd2935265:01crwdnd2935265:01crwdne2935265:0

    • Remove the handle cover by pulling it towards the front of the saw.

    • The grip can sometimes become stuck and may require a decent amount of force to remove.

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  3. Ridgid GEN5X R8642 Gear Assembly Replacement: crwdns2935265:03crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 Ridgid GEN5X R8642 Gear Assembly Replacement: crwdns2935265:03crwdnd2935265:02crwdnd2935265:02crwdne2935265:0

    • Use a T20 Torx screwdriver to remove the nine M4 X 16mm screws from the plastic housing.

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  4. Ridgid GEN5X R8642 Gear Assembly Replacement: crwdns2935265:04crwdnd2935265:01crwdnd2935265:01crwdne2935265:0

    • Use a JIS #1 screwdriver to remove the two M4 x 25mm screws on both sides of the metal housing.

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  5. Ridgid GEN5X R8642 Gear Assembly Replacement: crwdns2935265:05crwdnd2935265:01crwdnd2935265:01crwdne2935265:0

    • Remove one half of the plastic housing using a spudger so that the internal system is exposed.

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  7. Ridgid GEN5X R8642 Gear Assembly Replacement: crwdns2935265:06crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 Ridgid GEN5X R8642 Gear Assembly Replacement: crwdns2935265:06crwdnd2935265:02crwdnd2935265:02crwdne2935265:0

    • Remove the one 16mm T20 screw that holds the grip support onto the saw.

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  8. Ridgid GEN5X R8642 Gear Assembly Replacement: crwdns2935265:07crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 Ridgid GEN5X R8642 Gear Assembly Replacement: crwdns2935265:07crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 Ridgid GEN5X R8642 Gear Assembly Replacement: crwdns2935265:07crwdnd2935265:03crwdnd2935265:03crwdne2935265:0

    • Remove the five T20 Torx screws from the gear assembly cover and pull the cover off.

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  9. Ridgid GEN5X R8642 Gear Assembly Replacement: crwdns2935265:08crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 Ridgid GEN5X R8642 Gear Assembly Replacement: crwdns2935265:08crwdnd2935265:02crwdnd2935265:02crwdne2935265:0

    • Carefully remove the motor making sure not to harm any of the wires that are attached. Place motor gently out of the way.

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  10. Ridgid GEN5X R8642 Gear Assembly Replacement: crwdns2935265:09crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 Ridgid GEN5X R8642 Gear Assembly Replacement: crwdns2935265:09crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 Ridgid GEN5X R8642 Gear Assembly Replacement: crwdns2935265:09crwdnd2935265:03crwdnd2935265:03crwdne2935265:0

    • Remove the orbital switch by pulling straight up on it.

    • Be careful to not lose the spring and pin that is inside of the switch.

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  11. Ridgid GEN5X R8642 Gear Assembly Replacement: crwdns2935265:010crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 Ridgid GEN5X R8642 Gear Assembly Replacement: crwdns2935265:010crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 Ridgid GEN5X R8642 Gear Assembly Replacement: crwdns2935265:010crwdnd2935265:03crwdnd2935265:03crwdne2935265:0

    • Remove the gear assembly by pulling it straight up.

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  12. Ridgid GEN5X R8642 Gear Assembly Replacement: crwdns2935265:011crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 Ridgid GEN5X R8642 Gear Assembly Replacement: crwdns2935265:011crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 Ridgid GEN5X R8642 Gear Assembly Replacement: crwdns2935265:011crwdnd2935265:03crwdnd2935265:03crwdne2935265:0

    • Pull the pin holding the metal guide housing in place.

    • Slide the metal guide housing back off the gear assembly.

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  13. Ridgid GEN5X R8642 Gear Assembly Replacement: crwdns2935265:012crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 Ridgid GEN5X R8642 Gear Assembly Replacement: crwdns2935265:012crwdnd2935265:02crwdnd2935265:02crwdne2935265:0

    • Remove the guide bushing by pulling up on it.

    • Then slide the pin out that holds the gear assembly and blade clamp assembly.

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  14. Ridgid GEN5X R8642 Gear Assembly Replacement: crwdns2935265:013crwdnd2935265:01crwdnd2935265:01crwdne2935265:0

    • Slide the blade clamp assembly off the gear assembly.

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

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Josh Wagoner

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Western Carolina University, Team S1-G3, Virtue Spring 2019 crwdns2935289:0Western Carolina University, Team S1-G3, Virtue Spring 2019crwdne2935289:0

WCU-VIRTUE-S19S1G3

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When reassembling with new gear, does gear needs to be greased?

Syoma Zv - crwdns2934203:0crwdne2934203:0

When reassembling after disassembly, cleaning gear case and all parts, how much is the right amount of grease for this gear box.

R Bulley - crwdns2934203:0crwdne2934203:0

Can anyone tell me how much grease to put in the gear case of a Ridgid R8642 Reciprocating saw when gear case is empty and clean.

R Bulley - crwdns2934203:0crwdne2934203:0

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