How to Replace the Blade Pulley on a Milwaukee Band Saw

Does your band saw seem to have a wobble? You might need a new blade pulley. The blade pulleys might be more commonly called blade wheels. They are the two wheels on your saw that the band saw blade rides on. Each wheel has a tire for traction (so that the blade doesn't slip). One common problem with the wheels is damage caused by contact with the blade (if the tires are allowed to wear out). The wheels contain two bushings that act as bearings between the wheel and the shaft. If these bushings are allowed to completely wear out, the shaft will wear into the wheel.

Let's get started.

REMOVING THE BLADE PULLEY   1. Remove the blade pulley cover.

a. Remove three screws securing the blade pulley cover.

b. Remove the blade pulley cover.

  2. Remove the blade pulley.

a. Use retaining-ring pliers to remove the retaining ring from the blade pulley shaft.

b. Remove the nylon washer.

c. Remove the blade pulley from the saw.

  3. Remove and inspect the tire.

a. Remove the tire from the blade pulley.

b. Inspect the tire for damage. If the tire is worn, stretched or cracked, it should be replaced.

  4. Remove and inspect the bushings.

a. Use a bearing press to press the bushings out of the blade pulley.

b. Inspect the bushings for damage. If the bushings are worn or damaged, they should be replaced.

INSTALLING THE NEW BLADE PULLEY

  5. Install the bushings.

a. Use a bearing press to press the bushings into the new blade pulley.

  6. Install the tire.

a. Align the cogs on the new blade pulley with the grooves on the tire.

b. Stretch the tire onto the blade pulley and work it around the edges (until it is smoothly seated).

  7. Install the blade pulley.

a. Install the blade pulley onto the shaft. (When replacing the rear blade pulley, you will need to rotate the pulley until it is aligned with the drive pulley beneath it.)

b. Install the nylon washer.

c. Secure the blade pulley with the retaining ring.

REASSEMBLING THE UNIT

  8. Reinstall the blade pulley cover.

a. Install the blade pulley cover.

b. Secure the blade pulley cover with the three screws.