Symptom	Problem	Repair	Comments	
Doesn't shift properly	Shifter wire out of either ring gear	Replace  transmission	shift wire, gearbox and shift cam are damaged	
	Shifter wire out under shift cam			
	Extra spindle lock pin in transmission			
	Damaged shift cam			
	Crooked detent spring	Re-adjust spring position	look for damaged detent path in gearcase	
	No grease on detent spring	Place a little grease in detent path		
	Shifter wire hits gearcase	Replace  GEARCASE	DW980, DW983, DW987 (DC 200128-31only)	
	Spindle lock retainer upside down	Re-locate retainer		
Won't stay in gear	Missing detent spring	Install detent spring		
	Damaged gearcase splines	Replace  transmission		
Clutches in drill - no output	Missing clutch components	Replace  transmission	Install missing component if available	
	Gearbox splines stripped		Usually clutches in speed 2 or 3, but not both	
	Gearbox clutch channel damaged		Sometimes cracked	
	Small clutch pin wear		Replace pin if available	
				
Very heavy clutch in speed 1, collar setting 1	Normal	No repair, use speed 3		
Noise	Motor bearings	Replace motor	Check bare motor for noise	
	Damaged motor pinion			
	No transmission grease	Add Molykote grease to trans	Check all three reductions	
	Contamination in gear teeth	Replace transmission		
	Missing/damaged gears			
	Extra spindle lock pin in transmission		Gears are damaged	
	Missing spindle lock damper		Install damper if available	
	Damaged clutch channel			
"Clank" sound when trigger is released	This is normal operation of spindle lock		Inspect assembly if excessive "clank"	
Hammers in drill/allways hammers	Hammer mechanism not set correctly	Rotate collar to hammer, check hammer, then try drill position		
	Missing cam return spring	Install return spring	Hoop shaped spring	
	Cam return spring installed incorrectly	Replace cam return spring	Spring is now damaged	
	Fixed ratched installed upside down	Re-position fixed ratchet		
	Missing spindle or hammer return spring	Replace  Gearcase assembly	Install missing spring 	
No hammer	Missing cam ring, fixed ratchet	Replace Gearcase assembly	Install missing part 	
	Rotating ratched upside down	Replace spindle 		
	Extra spindle spring	Replace  spindle 		
No run	Stuck brush	Replace  brush box assembly	Complete set	
	Leads not connected	Connect leads	Brush or switch side	
	Shorted wire at heat sink	Replace lead wire	Locate wire correctly, away from heat sink	
	Motor locked up	Replace motor		
	3rd ring gear broken	Replace transmission		
	Bad switch	Replace switch		
Collar stuck in drill or hammer	Small clutch pin on top of the ring gear peak	Loosen four screws 1 turn and turn the collar		
	Missing collar insert	Replace Gearcase assembly	Replace collar if available	
	Collar ramp is dented by clutch pin		Replace collar if available	
Collar stuck and won't go above position 21	Small clutch pin on top of the ring gear peak	Clutch in reverse in low clutch setting	Rear transmission plate may be warped	
Stiff collar	Excessive paint on front metal cap	Replace  Gearcase assembly	Replace cap if available	
	Damaged clutch channel 			
Bit runout	Chuck jaws not aligned	Replace chuck		
	Chuck jaws worn			
	Chuck jaws cracked			
	Bent spindle	Replace spindle 		
Chuck sleeve stuck	Chuck was slammed full open	Try to free the sleeve, or replace chuck		
Chuck clicking sound	OK condition	Close chuck fully and re-open		
Vibration	Bent motor shaft	Replace motor		
	Damaged fan	Replace motor		
Poor performance	Broken shunt	Replace brush box assembly	Complete set	
	Stuck brush			
	"Cooked" motor	Replace motor	Check lead wires also