How to Replace the Pulley Bearings on a DeWALT Portable Band Saw

There are two pulley bearings on each of your band saw's drive pulleys. The bearings allow the drive pulleys to rotate on the shafts. The bearings are durable needle bearings, but eventually they will fail and need to be replaced. When the pulley bearings begin to wear, the drive pulley may begin to wobble from side-to-side (due to the extra "play" in the bearings).

Let's get started.

REMOVING THE PULLEY BEARINGS   1. Remove the drive pulley.

a. Remove the (3) small outer screws from the drive pulley.

b. Remove the screw from the center of the drive pulley.

c. Lift the drive pulley away from the saw.

  2. Remove the pulley bearings.

a. You will need an arbor press to remove the bearings from the drive pulley.

b. Place the drive pulley on the base of the arbor press (with the exterior side of the drive pulley facing down).

c. Locate a socket that is slightly smaller (in diameter) than the pulley bearings.

d. Position the socket on the bearing race.

e. Press both pulley bearings out of the bottom of the drive pulley.

INSTALLING THE NEW PULLEY BEARINGS

  3. Install the pulley bearings.

a. Position one of the new pulley bearings in the center of the drive pulley (in the hub).

b. Locate a socket that is slightly larger (in diameter) than the outer race of the new pulley bearing.

c. Position the socket over the bearing race.

d. Press the new pulley bearing into the drive pulley.

e. Invert the drive pulley on the arbor press.

f. Position the second pulley bearing in the center of the drive pulley.

g. Switch back to the original socket (used to remove the bearings).

h. Position the socket over the second pulley bearing.

i. Press the second pulley bearing into the drive pulley until it is flush with the bottom of the shoulder on the drive pulley.

REASSEMBLING THE UNIT

  4. Reinstall the drive pulley.

a. Align the tabs on the back of the drive pulley with the notches in the sprocket. (It helps to have the sprocket centered as much as possible on the spindle before installing the drive pulley.)

b. Install the drive pulley onto the sprocket.

c. Install the plastic washer onto the (center of the) drive pulley.

d. Install the metal washer over the plastic washer.

e. Secure the drive pulley with the three outer screws and the center screw.