How to Replace the Gear Case Gasket on a DeWALT Angle Grinder (Model D28402)

If leaking seals and service bills are grinding at your nerves, it's time to face the fix. Whether grinding is an occasional activity, or part of your daily grind; eReplacementParts.com provides the parts, procedures and facts you need to fearlessly fix what fails you.

The gear case gasket forms a seal between the lower gear case and the gear case cover. Its purpose is to keep the lubrication (grease) from leaking out of the assembly. Over time, the gasket can become brittle, and you may notice traces of grease seeping from the gear case cover. This article will show you how to quickly install a new gear case gasket on a DeWALT D28402 angle grinder. Let's get started.

  REMOVING THE GASKET [top] 1. Remove the side handle.

Unscrew and detach the side handle from the grinder.

  2. Remove the guard.

Raise the guard latch.

Rotate the guard until the lugs disengage.

Remove the guard from the grinder.

  3. Remove the gear case gasket.

Remove the (4) retaining screws from the gear case cover.

Remove the gear case cover.

Remove the gear case gasket from the gear case cover.

  INSTALLING THE NEW GASKET [top] 4. Install the new gear case gasket.

Align the tabs on the new gasket with the indents on the gear case cover.

Work your way around the gasket; pressing along the entire perimeter to ensure that all segments of the gasket are properly seated in the channels on the cover.

  REASSEMBLING THE UNIT [top] 5. Reinstall the gear case cover (and new gasket).

Install the gear case cover (and gasket) onto the gear case assembly.

Secure the gear case cover with the (4) screws.

  6. Reinstall the guard.

Install the guard onto the grinder.

Press and rotate the guard to engage the lugs.

Lower the latch to secure the guard.

    7. Reinstall the side handle.

Thread the side handle onto the gear case assembly.

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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