Question about Dewalt DW618 Router

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How to open the case in order to replace the bearings

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This is a serious disassembly and re-assembly.

Not only do you need to remove the yellow plastic cover end, but also disassemble the collet end. Depending on which version 618 you have it may have screws on the collet end or just a large nut. Sometimes you can't see the screws because they are plugged or covered with wood dust. The bearing is press-fit on the shaft on at least one end and requires an arbor press and special pressing sleeve. So you can only get so far on one of the 618 models then you have to use the arbor press to finish disassembly. The outside of the bearing sits in a very very close fit bore in the aluminum housing, which often becomes very difficult to disassemble without heating the aluminum housing. One bearing (top) must be pressed off the shaft and the replacement bearing precisely positioned where the old one was, so you need to measure with an inside snap gage, a dial caliper tail or depth micrometer to assure proper re-positioning. If you don't get it right then the motor shroud will rub the housing and the shaft won't sit right in the lower bearing.

You also need to replace the brushes while you have it apart. Between the labor, brushes and bearings cost you are better off taking it to a DeWalt service center - but even so, the cost to replace the router would usually be less than the service cost if it is out of warranty! Be very careful to make sure if you or anyone does do this job that the replacement bearings are properly rated for high speed - otherwise you'll be doing the job again in a few months of use.

Posted on Mar 01, 2009

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