Porter Cable Internal Switch Repair Guide

[statusdetailing]

My Porter Cable DA was having intermittent switch problems, and eventually got bad enough that I was going to have to replace the unit or fix the problem.

I took the unit apart and was sure I would find a loose connection, but found nothing.

What I found was the the main switch on the outside of the unit is actually a dummy switch, which by an internal arm triggers a real, internal switch which controls the unit. It is the small black box with switch on top, at the end of the yellow wire. Pictured here:

Here it is, removed and disassembled.

Eventually what I found, was that the connecting plates inside the switch were covered in a carbon/residue deposit as you can see here:

Here it is after I cleaned it with a brass wire brush:

Note that there are two connectors/plates, left and right:

Replace the wires, and snap switch back on to the box. Reassemble unit. You are ready to polish some paint!

[BillE]

OUTSTANDING!

That will help a LOT of people.

Maybe the mods could make a 'sticky' for this...hint hint.

Bill

[lawrenceSA]

Thanks for posting this. Very useful info

[CrayBrown]

Noted good sir. Thank you for the fine breakdown.

[bfowkes]

This is great. My problem is that my switch really is bad. Does anyone know how to remove the electrical connector for the switch? I have a new switch to replace the bad one but cannot for the life of me figure out how to get that goofy electrical connector off.

To be clear I am talking about the orange connector that you can see in pictures 3 and 4.

[statusdetailing]

It looks like there are snaps or grooves or something on the sides of that connector. Try to squeeze those or push something in there, like a punch or screwdriver, while you pull the two pieces apart. Might be tricky.

[bfowkes]

Yes it is quite tricky. I will be taking another look at it tonight.

[DaveT435]

Bump

[statusdetailing]

Bump

Are you having issues with your PC? Mine's still going strong since cleaning up the switch. The poor thing is mostly just a carpet scrubber these days though.

[Lanny]

Even more tricky is getting that switch back together. I've been trying for two hours to get the spring to stay in place. Any secrets to this?