How to Replace the Fan on a DeWALT Angle Grinder (Model D28402)

If broken parts and faulty starts are grinding on your nerves, it's time to face the fix. Whether you are a grinding pro or seasonal grinder, eReplacementParts.com provides the parts, procedures and facts you need to fearlessly fix what fails you.

The separator fan mounts to the rear of the armature. Its purpose is to separate debris from the incoming airflow that cools the grinder's motor. While the component is generally quite durable, large pieces of debris do occasionally enter the motor housing, which can damage to the fan.

As a fan of fast DIY projects, you will appreciate the simplicity (and savings) of replacing the separator fan in your DeWALT 28402 angle grinder. Let's get started.

  REMOVING THE FAN [top] 1. Remove the top half of the handle assembly.

Remove the (5) retaining screws.

Remove the top half of the handle assembly.

  2. Separate the handle from the field case.

Remove the paddle assembly.

Remove the lock-on button assembly.

Separate the handle from the field case.

  3. Remove the fan.

Press and hold the motor-lock button (on the gear case) to prevent the motor from spinning.

The separator/fan is reverse-threaded; rotate the fan in a CLOCKWISE direction to loosen it.

Remove the fan from the armature.

  INSTALLING THE NEW FAN [top] 4. Install the fan.

Press and hold the motor-lock button (on the gear case) to prevent the motor from spinning.

The separator/fan is reverse-threaded; rotate the fan in a COUNTERCLOCKWISE direction to secure it to the armature.

  REASSEMBLING THE UNIT [top] 5. Reconnect the handle assembly to the field case.

Partially connect the lower half of the handle assembly to the field case.

Tuck the wires into the designated slots and channels on the assembly.

Connect the lower half of the handle to the field case (manipulate the two components until they "snap" into place).

  6. Reinstall the lock-on button.

One side of the lock-on button contains a small tab. This tab should be installed facing the armature.

Install the lock-on button into the handle.

  7. Reinstall the paddle assembly.

Install the paddle assembly into the handle; ensure that the "tail" is positioned above the switch button, and the "fulcrum" is seated within the recess in the handle.

  8. Reinstall the top half of the handle assembly.

Partially install the top half of the handle assembly.

Align the posts (on the fulcrum and the lock-on button) with the recesses in the top of the handle.

Before securing the handle with the screws, test the paddle and the lock-on button for proper functionality.

Secure the handle with the screws.

You can't place a value on a job well done, unless you did it yourself. (Which you did.) Now you can place that value back into your own pocket. (Or into your business.) Not only did you refine your grinder at a fraction of the cost of replacement; you have expanded your skills far beyond the daily grind.

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