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Dewalt DW511 Hammer Drill Gearcase Replacement

Dewalt DW511 Hammer Drill Gearcase Replacement

Andrew Grayson Crawford

Andrew Grayson Crawford and one other contributor

Last updated on December 9, 2020

35 - 50 minutes
Moderate

Introduction

Go to step 1

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.

What you need

Tools

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  1. Dewalt DW511 Hammer Drill Gearcase Replacement, Back Cover: step 1, image 1 of 3 Dewalt DW511 Hammer Drill Gearcase Replacement, Back Cover: step 1, image 2 of 3 Dewalt DW511 Hammer Drill Gearcase Replacement, Back Cover: step 1, image 3 of 3

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

    Edit

  2. Dewalt DW511 Hammer Drill Gearcase Replacement: step 2, image 1 of 3 Dewalt DW511 Hammer Drill Gearcase Replacement: step 2, image 2 of 3 Dewalt DW511 Hammer Drill Gearcase Replacement: step 2, image 3 of 3

    • 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.

    Edit

  3. Dewalt DW511 Hammer Drill Gearcase Replacement, Power Cord: step 3, image 1 of 2 Dewalt DW511 Hammer Drill Gearcase Replacement, Power Cord: step 3, image 2 of 2

    • Firmly grab the body of the trigger.

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

    Edit

  4. Dewalt DW511 Hammer Drill Gearcase Replacement: step 4, image 1 of 3 Dewalt DW511 Hammer Drill Gearcase Replacement: step 4, image 2 of 3 Dewalt DW511 Hammer Drill Gearcase Replacement: step 4, image 3 of 3
    Tool used on this step:
    Tweezers
    $4.99
    Add To Cart

    • 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.

    Edit

  5. Dewalt DW511 Hammer Drill Gearcase Replacement: step 5, image 1 of 3 Dewalt DW511 Hammer Drill Gearcase Replacement: step 5, image 2 of 3 Dewalt DW511 Hammer Drill Gearcase Replacement: step 5, image 3 of 3

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

    • Carefully wiggle the wire loose.

    • Pull the wire slowly until it comes out.

    Edit

  7. Dewalt DW511 Hammer Drill Gearcase Replacement: step 6, image 1 of 1

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

    Edit

  8. Dewalt DW511 Hammer Drill Gearcase Replacement, Brushes: step 7, image 1 of 3 Dewalt DW511 Hammer Drill Gearcase Replacement, Brushes: step 7, image 2 of 3 Dewalt DW511 Hammer Drill Gearcase Replacement, Brushes: step 7, image 3 of 3

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

    • Remove the brush from its holding.

    Edit

  9. Dewalt DW511 Hammer Drill Gearcase Replacement: step 8, image 1 of 2 Dewalt DW511 Hammer Drill Gearcase Replacement: step 8, image 2 of 2
    Tool used on this step:
    Tweezers
    $4.99
    Add To Cart

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

    • Carefully wiggle the wire loose.

    • Pull the wire slowly until it comes out.

    Edit

  10. Dewalt DW511 Hammer Drill Gearcase Replacement, Lever Assembly: step 9, image 1 of 3 Dewalt DW511 Hammer Drill Gearcase Replacement, Lever Assembly: step 9, image 2 of 3 Dewalt DW511 Hammer Drill Gearcase Replacement, Lever Assembly: step 9, image 3 of 3

    • Remove two 45 mm T20 Torx screws.

    • Remove one 30 mm T20 Torx screw.

    Edit

  11. Dewalt DW511 Hammer Drill Gearcase Replacement: step 10, image 1 of 1

    • Pull off the top case and set it aside.

    Edit

  12. Dewalt DW511 Hammer Drill Gearcase Replacement: step 11, image 1 of 3 Dewalt DW511 Hammer Drill Gearcase Replacement: step 11, image 2 of 3 Dewalt DW511 Hammer Drill Gearcase Replacement: step 11, image 3 of 3

    • 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.

    Edit

  13. Dewalt DW511 Hammer Drill Gearcase Replacement: step 12, image 1 of 1

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

    Edit

  14. Dewalt DW511 Hammer Drill Gearcase Replacement, Gearcase: step 13, image 1 of 3 Dewalt DW511 Hammer Drill Gearcase Replacement, Gearcase: step 13, image 2 of 3 Dewalt DW511 Hammer Drill Gearcase Replacement, Gearcase: step 13, image 3 of 3

    • Hold the hammer drill tool firmly by the handle.

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

    Edit

  15. Dewalt DW511 Hammer Drill Gearcase Replacement: step 14, image 1 of 3 Dewalt DW511 Hammer Drill Gearcase Replacement: step 14, image 2 of 3 Dewalt DW511 Hammer Drill Gearcase Replacement: step 14, image 3 of 3

    • 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.

    Edit
Conclusion

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

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