Milwaukee 5262-21 Reduction Gear Assembly Replacement

Introduction

This guide will show you how to take the tool apart all the way down to the gears so that you can replace the reduction gear assembly. The reduction gear assembly can fail due to wear and tear. If you are experience grinding or slipping issues in the gearbox of your rotary hammer, the cause may be due to a faulty reduction gear assembly.

What you need

Step 1 Housing Assembly

Milwaukee 5262-21 Reduction Gear Assembly Replacement, Housing Assembly: step 1, image 1 of 1

Remove the ten 19mm T20 Torx screws shown in red.

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Step 2

Remove the red Housing Assembly by lifting it up off of the tool.

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Step 3 Reduction Gear Assembly

Milwaukee 5262-21 Reduction Gear Assembly Replacement, Reduction Gear Assembly: step 3, image 1 of 2

Milwaukee 5262-21 Reduction Gear Assembly Replacement, Reduction Gear Assembly: step 3, image 2 of 2

Remove the two 10mm T-10 Torx screws that attach the top brush holders to the motor housing.
Remove the two 10mm T-10 Torx screws that attach the bottom brush holders to the motor housing.

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Step 4

Using a metal spudger, pry off each brush holder.

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Step 5

Milwaukee 5262-21 Reduction Gear Assembly Replacement: step 5, image 3 of 3

Remove the four 37mm T20 Torx screws shown in red.

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Step 6

Pull the front portion of the tool out from the motor housing.

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Step 7

Milwaukee 5262-21 Reduction Gear Assembly Replacement: step 7, image 3 of 3

Remove the two 11.5mm T10 Torx screws shown in red.

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Step 8

Pull the 120V armature assembly out of the diaphragm assembly.

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Step 9

Using a metal spudger, pry the diaphgram assembly out of the gear case.

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Step 10

Now that you have loosened the diaphragm, you can now pull it out of the gear case.

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Step 11

Milwaukee 5262-21 Reduction Gear Assembly Replacement: step 11, image 3 of 3

The diaphragm assembly will be lathered in grease. In order to move forward, you may want to give it a wipe down to remove any extra grease.
After removing some grease (if needed), remove the two 15mm T20 Torx screws shown in red.

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