Blade Case 153664-0

1. Remove old case, careful to not damage the Philips head screws
2. Drive pin out of the old case with drift to remove foot
3. Remove small rubber spacer from the old case where the main bearing is seated
4. Install new case, be sure to install spring for saw lock and small rubber spacer
5. Replace foot and I recommend replacing the pin with a bolt and nylock nut unless you have a press to install the curling pin.
6. Note all the fasteners are metric, I had to replace the Philips head screws with new and again I purchased an 8mm x 50mm bolt and nylock nut to attach the foot at the front of the saw.

The roll pin was so tight that I couldn't punch it through without fear of breaking or bending the connection point so I had to use a die grinder to cut through the roll pin.

Refer to diagram for Makita 5740NB.

BLADE CASE REPLACEMENT:
1. Remove bolt (1) and blade with allen wrench. Set aside bolt with inner and outer flanges (3&4).
2. Remove base plate (65) with phillips screwdriver.
3. Remove tension nut and angle plate from the front of the blade case.
4. Remove tension nut and depth guide from blade case.
5. Remove tension spring (12) from safety cover (13).
6. Remove retaining ring (9) with split ring pliers.
7. Remove safety cover (13).
8. Remove two phillips screws and cover plate (21).
9. Remove one phillips screw and rubber sleeve (23).
10. Remove two phillips screws and bearing box (14).
11. Remove bearing assembly (5-8,15,16) keeping it together.
12. From the motor side, remove three long phillips bolts (48) that attach the motor section to the blade case.
13. Carefully work the blade case loose from the motor housing. There is a compression spring (40) that will try to get away from you that keeps tension on the shaft lock (38).
14. With the blade case free (and the tension spring found), add a little lubricant like PB Blaster or WD-40 to the spring pin (61) holding the angular guide (55) to the leading edge of the blade case.
15. Use a drift punch to carefully drive out the pin and remove the angular guide.
16. Reassemble in reverse of above, transferring components to the new blade case.
TIP: attach the shaft lock to the motor side of the blade case, installing the runaway tension spring right before attaching to the motor housing. If the armature assembly (36) was removed during your disassembly, you will need to remove the two brush holder caps (49) and pull the brushes (50) out a bit so the shaft will reseat.

HANDLE COVER
1. Remove phillips screws holding the handle cover (41) to the motor housing (51).
2. Carefully pry the two sections apart. There is a tiny plastic alignment pin that can easily break off near the switch. If it is already broken, which might be the case if you are replacing this part, be sure to remove what's left of the pin from the hole, otherwise the new part will not seat, and if you force it, you'll break the new one, as well.
3. Reassemble in reverse order.

IMPORTANT ADVICE
Be patient, take your time, and keep your parts organized. As long as you can keep track of components and are confident you can assemble at a later date, do the disassembly of your saw and check over all components for broken, bent, or otherwise damaged or worn parts needing replacement. That way you can order all pieces needed at once and save time and excess shipping charges. Had a bad switch I had to order once I removed the handle cover, delaying assembly. With any power tool, take extra safety precautions when testing after repair. Check all fasteners after the first few uses to make sure everything is tight. Any loose bolts need a little threadlocker.

I had to remove the bent blade case and install a new one. To install was really easy, but one thing was hard. The 3/16" by 1 1/2" metal pin on the blade case and shoe was hard to remove it. it's tight(pressure). You got to punch it with a hammer, but you can....just slow (don't bend the new one!!!)