How to Replace the Switch on a DeWALT Grinder

Your grinder uses a basic toggle switch that breaks the circuit on both the hot and neutral wires. After thousands of cycles and years of use, the switch will wear out. Testing for a bad switch can be easily done using a multimeter.

Let's get started.

REMOVING THE SWITCH   1. Remove the brush doors.

a. Remove the screws securing the brush doors to the motor housing (one on each side of the motor).

b. Remove the brush doors from the motor housing.

  2. Remove half of the handle assembly.

a. Remove the screws securing the two halves of the handle assembly.

b. Remove one half of the handle assembly.

  3. Remove the switch.

a. Remove the screw securing the switch to the handle assembly.

b. Pull the switch assembly out of the handle housing to gain access to the switch wires.

c. Remove the switch insulator (paper) from the handle housing.

d. Note the location of the four wires on the switch (for reassembly).

e. Remove the screws securing the wire (eyelet) connectors to the switch.

f. Remove the switch from the grinder.

INSTALLING THE NEW SWITCH

  4. Install the switch.

a. Use the screws to connect the four wires to the new switch (in the same configuration as the original wires.

b. Install the paper insulator over the new switch.

c. Install the new switch assembly into the handle housing.

d. Secure the switch to the handle housing with the screw.

REASSEMBLING THE UNIT

  5. Reinstall the handle.

a. Tuck the switch and motor wires into the handle housing.

b. Install the outer half of the handle assembly.

c. Secure the handle assembly with the screws.

  6. Reinstall the brush doors.

a. Install the brush doors.

b. Secure the brush doors with the screws.