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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I have a Bosch 1617 EVS router, a couple of years old, one of several routers, so not a lot of hours on it. A minute or so after turning it on I get a burning smell. It doesn't smell when I run


Check the armature bearings, especially the lower one hear the collet. It's possible some of the liquid wrench got into the bearing and cleaned out the lubricating grease that's in there. If the bearing is dry or damaged, either from use or during the removal of the stuck collet it will cause the motor to work harder which causes heat buildup and eventually a burning smell. If you bent anything you would feel a very distinct vibration in the tool when you turned it on that wouldn't have been there before. The bigger the bend the greater the vibration.

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Router making a squeal noise and sparks from the brushes.


Squealing is usually associated with bad bearings. Sparks from the brushes is being caused by the motor pulling harder than usual because of the bad bearing. Sparks come from the carbon being burned off the brushes. I'd replace both, brushes are inexpensive and will make the tool work better and longer.

Sep 11, 2012 | Tools & Hardware - Others

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Loud whinning 7539


Noises like that are usually a bearing going, or gone, bad. If you keep running it eventually the alignment of the armature will be off enough to make contact with the field and one or both will get damaged enough to warrant replacement. Bearings run between $7 to $15 to replace. Armatures are $175 and Fields are $110 for your router.

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1 Answer

How do I replace the magnetic ring on DW618?


take out 4 screws on top of router. i used a large flat head but they are not flat head (some kind of combo with star type center). remove top could be a little stuck. you will see bearing in center. the magnetic ring sits underneath the bearing. you need a small bearing/gear puller to get bearing out. once out the magnetic ring goes flat side down over center shaft and then the bearing gets replaced over it. i just tapped the bearing down softly with a small hammer being careful not to break new magnetic ring.

May 04, 2011 | Dewalt DW618 Router

1 Answer

Need to replace broken dewalt 618 magnet ring.


you have to take four screws out from top of router. i used a large flat head screwdriver but actually the screw has a weird head like a cross between flat head and star. anyway once you remove cover you should see the bearing in the center. you need to use a bearing/gear puller to remove it. the magnetic ring lays just beneath the bearing. if its still there. mine was in pieces. clean out the mess and then the magnetic ring slides on flat side down. then LIGHTLY tap the bearing back into place. i used a small hammer. there didn't seem to be any lubrication in there so i didn't add any.

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1 Answer

My Freud 2000 router has started sparking where the brushes are and slows down. Increase in speed control to max blew a fuse. I have tried changing brushes to no avail. Is the problem the armature/winding?...


if that is the case it may be a better option to replace the router. check online for freud spares suppliers but make sure you order the correct part with correct model number as some of them do not accept returns

Dec 12, 2009 | Tools & Hardware - Others

1 Answer

My dewalt is not running freely ,the brushes are fine but i cant get the main body of to inspect the motor can you give any advice


Sounds to me like you have a burned up motor. The armature and the field have probably swollen from overheating and that is why you cannot remove the main body and also why it is not running freely. It is binding. Thats my first guess. My second guess would be that one of your bearings is bad causing it to not run wide open. If you could let me know the model number you are trying to open up I can give you some pointers as to how to accomplish it.

Oct 10, 2009 | Tools & Hardware - Others

1 Answer

Router runs slow


I still think that it is the bearings, especially since of the squealing noise which is a symptom of the bearing seizing up and the armature shaft would get hot transferring the heat to the motor housing. Give me the model number and brand and I will find a breakdown and part numbers for you and also if you give me your general location I will try and find someone local to get the parts.

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How do I disassemble a porter cable 1002 router? I am trying to get to the motor in order to clean out pieces of broken brushes.


How do I hold the armature still on a Porter Cable Model 1002 Router to take the nut off to change the inner bearing

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