How to Replace the Upper Bearing on a Porter Cable Router (690 Series)

Router bearings wearing out? It's time to face the fix. Whether you are a master carpenter or a weekend woodworker, eReplacementParts.com provides the parts, procedures and facts you need to fearlessly fix what fails you.

The upper armature bearing on a porter cable 690 series router is about half the size of the lower bearing. This means that the bearing usually wears out twice as quickly. Symptoms of a despairing ball bearing will be unusual sounds (such as ticking, squealing or screeching).

This article provides step-by-step instructions for removing and installing the upper (small) armature bearing on a Porter Cable 690 series router.

Let's get started.

  REMOVING THE BEARING [top] 1. Separate the motor from the base.

Open the clamp (using the clamp knob).

While holding the power unit, rotate the base CLOCKWISE until the lower pin in the motor housing is disengaged from the groove in the base.

Lift the power unit free from the base assembly.

  2. Remove the motor housing cap.

Remove the (2) screws from the motor housing cap.

Remove the motor housing cap from the motor unit.

  3. Remove the motor brushes.

Use a large screwdriver to loosen the brush cap.

Remove the brush cap.

Remove the motor brush.

Repeat this step to remove the second motor brush.

  4. Separate the power unit from the case.

Use a marker to draw a line across the intersection of the power unit and the front case. This line will be used in later steps to help realign and reassemble the unit.

Remove the (2) retaining screws from the power unit.

Use a rubber mallet to tap the power unit until it breaks free from the case.

Separate the power unit from the front case.

  5. Remove the upper (small) bearing.

Use a bearing-puller tool to remove the upper bearing from the armature.

  INSTALLING THE NEW BEARING [top] 6. Install the new upper bearing.

Apply a thin coat of grease to the end of the armature shaft.

Align the new bearing with the shaft.

Locate a socket that is approximately the same diameter as the inner race of the bearing.

Position the socket squarely upon the inner race of the bearing.

Tap the end of the socket with a rubber mallet until the new bearing is fully seated on the shaft.

  REASSEMBLING THE UNIT [top] 7. Reconnect the power unit to the case.

Slide the armature (in the motor case) through the field (in the power unit).

Rotate the components as necessary to align the reference marks (made earlier) on the case and the power unit.

Secure the power unit to the case with the (2) screws.

  8. Reinstall the motor housing cap.

Inspect the wiring around the power unit for potential “pinch points.” Adjust the wires as necessary.

Install the motor housing cap onto the power unit.

Secure the motor housing cap with the (2) screws.

  9. Reinstall the motor brushes and caps.

Slide the motor brush into the brush holder.

Align the tabs on the motor brush with the slots on the brush holder and compress the brush (spring) into the holder.

Continue holding the compressed motor brush in place with one finger.

Carefully slide the brush cap into position over the compressed motor brush (as you remove your finger from the end of the brush). You may have to attempt this step a few times to get it right. The goal is to install the brush cap without allowing the tabs of the compressed motor brush to spring out of the slots in the brush holder.

Use a large screwdriver to secure the brush cap (do not overtighten).

Repeat this step to install the remaining motor brush and cap.

  10. Reconnect the motor unit to the base.

Set the motor unit into the base.

Rotate the base COUNTERCLOCKWISE until the upper guide pins motor are set in the groove of the base.

Tighten the clamp to secure the unit.

Dovetails. Rabbets. Dados. Grooves: The possibilities are as priceless as machines that create them. But you don't have to be a carpenter to cut out the middle-man. Repairing your own powered equipment is easy and economical when you follow our step-by-step guides. Not only did you restore your router at a fraction of the cost of replacement; you built on your ability to face the next fix, whatever it may be.

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