I am having trouble seperating the cabinet on the DW911. I removed all the obvious screws, however, the seams appear to be welded or glued shut. Is this the case, and if so, does anyone have any advise as to how to seperate the 2 halves of the case?
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Dewalt's DW106 does not have a set screw inside the keyless chuck to hold it on. This means the chuck was put on with enough lok-tite and torque to keep it on under most circumstances so getting it off will not be easy. If you're using the allen wrench-in-the-chuck method, give it a good firm whack until it breaks free.
First this has a static sensetive switch so you must do this at a static free work station!
After you open the too disconnect the motor leads (Remember which one goes where) then take the shift lever out of the transmission. It just hooks in on the sides and will pop with a small screw driver blade. then you will have access to four #10 torx head screws that hold the transmission on to the motor. Remove those while holding the motor and transmission together. Carefully seperate them making sure all the pieces stay in the transmission. It's best to hold the assembely motor in the air when seperating them. Instal the new motor on the transmission by aligning the min on the motor with the notch on top of the transmission. Put in the for torx 10 screws. Reconnect the leads, put the shift lever back on making sure it aligns with the shift ring slots on the transmission. make sure the flat spring on the shift lever stayed on. If not find it or it will not stay in gear! Put the housing back together and you're done.
down inside the chuck head itself is a allen head screw,, it has reverse threads on it. if you have already removed this screw and the chuck is still stuck then you will need to use a small gear/pulley puller to get it to release.
(( note: if you do not have access to a puller -- stop by you local Dewalt repair shop and I am sure that they will pull the chuck off with their puller at no charge to you )).
open the chuck fully and it shoudl have a screw inside. Unscrew it, but be carefull, these screws are usually reversed - to uncsrew, rotate it clockwise. Once done, put allen key into chuck (short side in), fasten the chuck to hold allen key well and hit the key with hammer - counterclockwise direction. You might want to verify this procedure with someone else as I have no experience with Dewalt, but this way it works for Makita, Metabo, Narex, ... then why not for Dewalt?
These tools have panetry gearboxs to give maximum torque foe lightweight gearing. A common problem with the older DeWalt drills was the gear selector legs coming adrift. This is (potentially) an easy fix. First of all, the obvious stuff. Remove the battery and press the trigger to release any static/stored power. Undo all the screws and seperate the two halves. Try to keep all the internals in the back half like this... http://lib.store.yahoo.net/lib/mendingshed/DW958mainimage1.gif
Now check the metal legs coming down from the gear selector slide. They should be sitting through the sides of the gearbox, and located into the sides of a ring gear. They used to pop out of this gear which would stop it being pushed fully into position.
Yes, the DeWalt radio will recharge the batteries, from the 12 Volt to 18 Volt versions. However, even with the radio plugged into an AC outlet, you have to either have the radio turned on, or have the unit in the AUX setting, in order for the batteries to get charged.
It typicaly takes about an hour +/- to fully charge a discharged battery. I normally don't put batteries directly into a charger right after they become discharged from being used in a tool, since they are still warm from use and charging them will generate more heat in the recharging
Heat is the enemy of rechargeable batteries, so to get the longest working life out of your batteries, I'd let them cool down first, before recharging them, unless you absolutely need to use them right away, then go ahead and recharge them. If you can delay recharging them until they've cooled down, you'll get a more fuller recharge out of them.