How to Repair a DeWALT Cordless Drill/Driver – Part 2

This project is continued from Part 1.


DeWALT Drill/Driver Clamshell Repair Part

The new clamshell set that I ordered for $9.87 from DeWALT ServiceNet® for the broken drill handle arrived. The new clamshell is identical to the original as expected. Replacing the clamshell only requires a torx bit to disassemble the drill.

DeWALT Cordless Drill Repair: Replacement Plastic Clamshell

DeWALT® Cordless Drill/Driver Disassembly

Taking apart my DeWALT DC987 cordless drill was easy:

  1. Turn the torque setting to the lowest value to relieve the pressure on the clutch plate.
  2. Remove the 4 torx screws from the gear case/keyless chuck unit. Point the drill downward and slide the gear case out of the clamshell, taking care not to let the clutch plate and gears fall out of the gear case.
  3. Remove the torx screws from the clamshell handle and end cap.
  4. Lift off the left half of the clamshell handle.
  5. Lift out the motor and switch assembly.

Layout the parts as shown to organize your work:

DeWALT Cordless Drill/Driver Disassembly

The design and minimal parts count is amazing when you think about.

DeWALT Cordless Drill/Driver Reassembly

Reassembly is just putting things back together in reverse order. The gear case/keyless chuck unit is the last part to be attached.

DeWALT Cordless Drill/Driver: Motor and Switch Reassembly

A slender torx screwdriver was necessary to reach the two screws set deeply in the bottom handle just above the battery.

Grease the DeWALT Cordless Drill/Driver Gears

The old grease was a bit dirty and some grease was lost on my fingers after two reassembly cycles. I wiped away the old grease on the motor face, clutch plate and gear case before applying a general purpose lithium gear grease.

DeWALT Cordless Drill/Driver: Lithium General Purpose Grease

I used a screwdriver to dip the grease from the cartridge and packed the gears with my fingertip. Here’s the new grease applied to the DeWALT gears:

DeWALT Cordless Drill/Driver: General Purpose Gear Grease

After greasing the gears, reattach the gear case to the clamshell handle with the 4 torx long screws.

DeWALT Bit Clip Holder

The new clamshell didn’t include the bit clip, but it’s easy to install the clip on the new handle.

DeWALT: Transfer the Bit Clip to the New Handle

The metal bit clip has two retaining “wings” that hold it in the handle. Remove the bit clip by pressing the tip of a small screwdriver against the wing to release it, the clip will pop out.

DeWALT Cordless Drill/Driver: Bit Clip Removal

Snap the bit clip into the new handle by pressing it in with your finger tip until it clicks in place:

DeWALT Cordless Drill/Driver: Broken Handle Repair

DeWALT Cordless Drill/Driver Label

I forgot to order new DeWALT labels for the clamshell – these are available on DeWALT ServiceNet® for less than $1.

The drill is good as new, looks new, runs great and the repair parts cost me less than $10 plus shipping. Now I can spend the money I saved on new tools that I don’t have!

Take care,

Bob Jackson

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3 Responses to How to Repair a DeWALT Cordless Drill/Driver – Part 2

  1. Brant Addy December 8, 2010 at 8:07 pm #

    Bob,

    thanks for taking the time to post this. your photos and description made me feel confident enough to work on my drills too. (I have 3 that are in need of repairs.) Nice illustrations and description.

    • Bob Jackson December 8, 2010 at 8:56 pm #

      Thanks for letting me know the article helped you!

  2. MAK February 21, 2012 at 4:49 pm #

    Great tutorial. I had to do a similar repair and was worried about the grease. I ended up calling DeWalt and they gave me #G-2008 Molykote as the type of grease, and N017298 as the DeWalt service part # to order it directly from them.

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