Variable Speed On-off Switch 2610912780

The tool is a Dremel Model 395 Type 5. The original switch was red with 5 speeds, and is no longer available. I took a chance buying the blue switch which has about 9 click positions. The fact is that the switch is a simple rheostat and the 5 positions of the original switch and the 9 click positions of the blue switch are really inconsequential. The blue switch works fine in the Type 5 tool. The videos provided online are good.

Remove the metal bail that is used to hang the tool. Remove the collet nut and collet. Unscrew the plastic cap from the nose of the tool. Using a Torx T-10 driver, remove the four screws that hold the body shell together. With the switch facing down remove the upper half of the shell. Carefully lift out the armature/field coil/switch assembly. The rear ball bearing may have a rubber vibration cushion around it. If so, remove and save it. Remove the two caps that hold the brushes in, and remove the brushes. Slide the armature assembly forward and out of the field coil assembly. Remove and retain the armature lock button and spring. Carefully pull the switch assembly straight back and off the field coil assembly; there are four prongs that connect the fields to the switch--don't bend them.

There are two power leads that connect to the switch assembly. Push a thin pick into the same hole that each wire enters and pull out the pick and the wire together.

Gently, but firmly, push the leads into the holes on the new switch. Pull on them to make sure they are properly captured. I found this to be the hardest part of the repair; the new switch did not capture the leads as firmly as the old switch did.

Assemble the new switch back onto the field coil assembly, making sure that each of the four prongs properly enter the switch connectors. Slide the armature assembly back into the field coil/switch assembly. Replace the rubber cushion back onto the rear ball bearing. Replace the armature lock button and spring back into the lower shell.

Fit the armature/field coil/switch assembly into the lower shell, being sure that the "handle" for the switch projects through the slot in the lower shell. Make sure that the armature lock button and spring are still properly located.

Guide the power wires through the channels in the lower shell to protect them from being pinched or cut when the the halves are tightened. Carefully reinstall the power cord strain relief in its recess in the lower shell.

Replace the upper shell and be sure that it fits comfortably with no strain or bending--it should not need to be forced. Reinstall the four Torx head screws that hold the shells together--snug, but do not over tighten.

Reinstall the brushes, noting that the curve in the brush faces should mate with the curved surface of the armature's commutator. Now would be a good time to install new brushes if the old ones are worn.

Replace the plastic ring on the nose of the tool and the hanging bail on the rear. Replace the collet and collet nut.

Put on eye protection. Make sure the tool is turned "Off". Plug it in and turn it "On" and check it at all speed settings.

Unscrew brush caps & remove brushes. Take collet cap & plastic nose off front. Unscrew 4 torx screws & split casings. Lift armature out of case & remove rubber damper cap off of rear bearing. Remove switch from back of armature & pull wire out of switch. Make sure you mark where wires go on switch. Reverse each step to put back together.

Side note take your time.

Removed and replaced variable speed switch, VERY critical to get armature housing and V/ speed switch lined up correctly to keep armature from making contact with armature housing and or causing commutator contact failure. Good as NEW!!!

Took it apart and replaced switch.

Removed 4 Torx screw and changed out the old parts for the new.

Opened the housing and disconnected the wires to the switch, and reinstalled the new one. The brushes just popped out, and the new ones went in. Closed the housing.

1. Remove the drive cap at the end of the Dremel (threads on to allow for adapting accessories).
2. Remove the covers and the brushes to the stator (2 total).
3. Remove the hook that allows you to hang the tool upright (just unclips from the end)
4. Remove 4 screws holding the body together and separate the halves of the body paying particular attention the pin and spring clip that allow you to tighten the head when replacing bits (located at the front end of the tool). These will need to be placed properly to allow for proper assembly.
5. Remove the bearing cover at the end of the drive assembly (rear of the tool)
6. Remove the drive assembly and separate the variable switch and power cord from the base.
7. Remove the wires from the switch with slight pulling pressure and install them into the new switch.
8. Install everything back in the reverse order of above.

Remove collar and brush caps and brushes from Dremel tool. Remove Torx screws and split case to remove speed module. Shaft lock will come off when case is split. Replace module and position shaft lock and lock spring and put case back together. This is the trickiest part. Make sure shaft lock is working and cord grip is positioned so that the power wires are clear of the armature. Reassemble in reverse order.

Removed the screws to open up the body.
Disconnected old switch from the white and black wires.
Installed new switch and reconnected the wires.
Reassembled the other half of the body to line up with holes, ensuring nothing was out of alignment so the rotary part of the tool spun freely.
Reattached the screws.
Unscrewed the caps where the spring-loaded brushes are located.
Popped out the old brushes.
Fit the springs over the new brushes and inserted back in the holes and refastened the caps.
Plugged it in and started it up!

1. Remove four screws which hold two halves of the tool together.
2. Remove brushes.
3. Separate halves.
4. Remove switch assembly.
5. Remove power leads from switch assembly.
6. Install leads into new assembly.
7. Reassemble tool using new assembly.