DeWalt DW505k dis assembly.

[Chupa]

I believe its a DW505 type 3.
DeWALT DW505 Parts List and Diagram - Type 3 : eReplacementparts.com

I was using a hole saw, and went from soft wood to metal pipe which ended up breaking the teeth on one of the transmission gears (Part #49).

I have a couple questions. The first being how can I get this gear off to replace it. The second is there anything else I should check for damage? A pawn inspection nothing else is obviously broken other then that gear. The last question is why is the grease so expensive? Could I just use black grease from the hardware store instead?

Thanks!

[Chupa]

Forgot to sign up for email notification on reply. doing that now!

[cmoorejack]

Hey Chupa,
I believe you have to remove the the selector assy [#40] and then the gear will slide out..[the selector may have to be lined up in a certain position to pop out] also check #39 gear for damage..
Holy crap, that is expensive grease..I think it is because it has to pass thu a weasel or some kind of a rodent first to get it just right..
Any kind of a good quality gear grease that you can get at any auto parts store should be ok for this application..
hope this is helpful..?
cmoorejack

[Chupa]

I do have the selector assembly out but the gear wont slide off. Im sure there's something else holding it on the spindle.

All the gears and whatnot are still inside the front assembly so im unable to get a good look as to what it could be. I THINK that if i am able to get it out of the front assembly (36) I would be able to figure it out. But I cant figure out how to do that lol. How would I go about getting the chuk off this mother?

[cmoorejack]

Hey,
You will need to remove the reverse screw inside the chuck and I believe you can hold on to the shaft with a wrench [behind the chuck] with a large size allen wrench clamped in the jaws you then can hit the allen with a sharp blow [hammer] and it should break free [lefty loosee]..The website has a link under the tool repair articles to better demonstrate this method.. There are some other tricks of the trade but try that one first.. [you may also have to remove both selectors to remove the gear train?]
http://www.ereplacementparts.com/rem...873_15176.html

[Lisa]

Hi Bill and cmoorejack,

We do have an article and a video that should help guide you through the removal of the drill chuck. Check it out: Removing a Drill Chuck : eReplacementparts.com

Please let me know if this helps or not. Good luck!

Have a great day
Lisa

[Chupa]

I see the reverse thread screw in there! The video and explanation helps a great deal. Im going to give it a go next time I can. Thanks guys!

[Lisa]

I see the reverse thread screw in there! The video and explanation helps a great deal. Im going to give it a go next time I can. Thanks guys!

Hey Chupa! So happy we can help! I'd love to know how it all turns out for you If you find any of your own hints along the way, please let us know, as I would love to include anything that can further help folks in the article and video updates.

Lisa

[Chupa]

I was trying to get the reverse threaded screww off and it was putting up a fight. I ended up putting the chuck in a vice to hold it so I could put all my force into turning the allen wrench. Im quite sure I was turning the correct way, clock wise when looking down the "barrel" of the chuck, and I ended up stripping the screw in there. It just snapped pretty much and the hex head is rounded out. I have no idea what to do now, I think im up a creek

Any ideas?

[cmoorejack]

Hey chupa,
Dang..!
no worries..but now you will have to drill out the head of the screw..kind of a pain but be patient and this too will pass..
be sure and use a new sharp bit if possible..once you drill the head off the screw hopefully the chuck will come off easily..?
good luck !
cmoorejack

[Chupa]

Got it done! The chuk is now off!

But it dident seem to help in my quest to get part #49 off. After looking at it again i fear that its only held on there by #52, which seems like its press fitted on the spindle. I dont think there's a clean way for me to get #52 off without destroying the spindle. If anyone has any suggestions as to how that would be great.

OR any instructions on getting the entire spindle with all the gears on it out of the gear housing would be very helpful too.

[cmoorejack]

Got it done! The chuk is now off!

But it dident seem to help in my quest to get part #49 off. After looking at it again i fear that its only held on there by #52, which seems like its press fitted on the spindle. I dont think there's a clean way for me to get #52 off without destroying the spindle. If anyone has any suggestions as to how that would be great.

OR any instructions on getting the entire spindle with all the gears on it out of the gear housing would be very helpful too.

Hey Chupa.. It is a press fit..which means it will need to be pressed off..[the best method is with a hydraulic press] if it is done correctly there will be no damage to the spindle..a bearing splitter and a bearing puller might work also but the press is the way to go...

[Chupa]

Unfortunately I don't have access to a press. I ended up setting the spindle, gear and all, in a vice so that when I waked the spindle it would fall though with the gear in question just sitting there on top of the vice. I had to hit it fairly hard a couple times but it did come off. I ordered the replacement parts last week.

I inspected the spindle and it looked like it survived my wacks intact. Ill find out if this is true or not when my replacement parts come in.

Im not sure how im going to press the gear on without a press though. that will be fun.

[bec98x]

To make it a little easier put the spindle in the freezer and put the gear on a hot plate. Or take it to a local repair shop and I am sure for a 5'er they will press it on.

[Chupa]

my parts shiped out today. Ill be putting the sucker back together next week. Ill let you know!

[Chupa]

Great news! Everything back together and working fine! My parts came in today and I went right to work.

I put the spindle in the freezer and the gear that needed to be fitted on the hot plate and they went together without much fuss. I placed the gear flat on a cracked open vice with some between it and the gear and "persuaded" them to fit a bit with the hammer. It worked fine. Seems like you can be somewhat forceful with the hammer on the hardened steel parts without there being much problems. I was cautious, giving it maybe a 50% force swing. The spindle and gear seemed undamaged so I continued putting it all back together and it works fine now.

Thanks everyone so much for all the help. You guys saved me from spending $100 for a brand new drill. I ended up spending about $17 total for the parts and a little bit of labor, and now that I know what im doing somewhat next time wont be so difficult. This past month has been a pain in the butt not having my power drill, now I can get back to work!

[imzaza]

Hey chupa,
Dang..!
no worries..but now you will have to drill out the head of the screw..kind of a pain but be patient and this too will pass..
be sure and use a new sharp bit if possible..once you drill the head off the screw hopefully the chuck will come off easily..?
good luck !
cmoorejack

I was following along with the same problem, only when done drilling off the head of allen screw the chuck remains fixed. Also there is no good place behind the chuck to place a wrench. Any help is appreciated. Just found this site. Great place you all have here. Wish i would of found it before. Thanks

Also I have a DW 505 type 1