How to Replace the Intermediate Gear on a Milwaukee Hole Hawg

The intermediate gear is one of several gears that make up the drive train in your drill. The gears both set the drill's speed, and increase the torque that the drill produces. Over time, the gears will wear. As they do, the drill might begin to sound louder, or make a clicking sound. If the gear fails completely, the motor will run, but the gear won't rotate.

Let's get started.

REMOVING THE INTERMEDIATE GEAR   1. Remove the motor cover.

a. Remove the (4) screws securing the motor cover to the motor housing.

b. Remove the motor cover.

c. Remove the wavy washer from the motor cover (or from the top of the armature).

  2. Remove the intermediate gear.

a. Pull the intermediate gear out of the gear housing.

b. Inspect the gear and the gear housing for extreme wear. If the intermediate gear has failed completely (to the point that the teeth on the gear are worn away or badly damaged), you will need to remove and replace the ALL of the grease in the gear housing and the motor cover. The recommended grease for this procedure is Milwaukee's Type-E grease.

INSTALLING THE NEW INTERMEDIATE GEAR

  3. Install the intermediate gear.

a. Lubricate the teeth of the new intermediate gear with (Milwaukee’s Type E) grease.

b. Lubricate the shafts of the new intermediate gear with (Milwaukee's Type-E) grease.

c. Install the new intermediate gear into the gear housing.

REASSEMBLING THE UNIT

  4. Reinstall the motor cover.

a. Install the wavy washer onto the armature bearing.

b. Install the motor cover.

c. Secure the motor cover with the (4) screws.