Has anybody tried to replace a clutch in a DeWalt cordless drill / driver?
I have an 18V DeWalt DC759 1/2" VSR and the clutch is slipping when I have it on the drill setting. It sounds just like it does when I'm driving screws on a lower setting. I'm curious if there is any way to adjust it before I start ordering parts.
I rebuilt one of those. Or rather, rebuilt it a couple times ~then~ threw parts at it. The gearbox is a staggeringly complex arrangement of planetary gears and sprag clutches. I was a bicycle mechanic long enough ago to have been conversant in Sturmey-Archer 3 and 5 speed hubs as well as the various coaster brakes and oddball Sachs Torpedo hubs - so the DeWalt gearbox was not impenetrable, but it is a very good mechanical puzzle.
Take it apart, but print out a parts diagram from one of the online parts site first, or take a bunch of pictures as you go.
BTW - I have the drill, and the hammer drill. They're pretty great and I've used them both for years quite hard.
I have no input other than to add I just hit the easy button on mine earlier this week and had the deWalt store rebuild it for $100. They replace the motor, clutches and body on mine. Looks like there's only about 10% of the impact driver that's original. I'd be interested in seeing if you come up with a solution as I'm sure mine will be worn out in a couple years again.
I can replace the clutch/transmission (#14) for about $32 plus shipping, so I might give it a shot.
I would consider it my own personal DeWalt 18 volt Paperweight.
I tore through 4 clutches in my 18V Dewalt in the space of 18 months. At that point I set it aside and bought a Bosch.
I think the 18V motor is just too much for that gearbox. The 14V units never had that problem.
I just finished it. Everything that Motomoron said was accurate. I got a new clutch / transmission from an eBay vendor for $38 total, including Priority Mail. It was difficult to remove allen screw #6 (left hand thread and red Loctite) and tricky to remove the chuck from the shaft but the rest was very straightforward and took less than an hour.
I opened up the old, bad gearbox and it was insanely complex.
This video helped with the chuck:
http://www.youtube.com/watch?v=Tt2X_au5soc&feature=player_embedded#at=13
