Porter Cable Router Repair – Replacing the Strain Reliever (Porter Cable Part # 901266)

Porter Cable Router Repair – Replacing the Strain Reliever (Porter Cable Part # 901266)

The power cord passes through the strain reliever
as it goes into the tool’s handle. The strain reliever gives extra support to
the cord preventing it from kinking, and rubbing against the handle. The strain reliever is made of rubber, and
will eventually harden and crack. Once it does, the cord is prone to kinking,
or the wire insulation can be rubbed through. Replacing the strain reliever is a repair
that you can do yourself, and I’m going to show you how.[music]Advertisement: Hi, I’m
Mark Sodja. Do it yourself repairs like these are easier
than you might think. From lawn machines to cordless drills, kitchen
mixers, outdoor grills, our how-to videos walk you through each repair from start to
finish, so doing it yourself means never having to do it alone. Let’s get started.Mark: I’ll begin by removing
the motor cap from the motor. I’ll also remove the wires from the switch. Now, I can remove the cord from the router. First, I’ll remove the grounding wire. Next, the two screws that secure the cord
clamp. Now, I need to cut away the connector that
secures the white cord wire to one of the red motor wires. As I cut this crimping connector away, I want
to lose as little of the wire length as I can, so I’ll cut within the connector itself.There’s
a ziplock tie that secures the wires. I’ll cut that away, and now, I can pull the
cord away from the router. Now, I”ll remove the old strain reliever from
the cord. Now, I can install the new strain reliever. The large terminal on the end of the black
wire won’t fit through the strain reliever, so I’m going to have to cut it off and replace
it. This will have to be ordered separately. I’ll cut through the terminal itself, so I
don’t lose any of the wire length.Now, I’ll place the new strain reliever over the wires,
and I’ll strip back about a quarter inch of insulation from the black wire and about three-eighths
from the white wire. Here, I have the new terminal. You may notice a strip of metal on the end
of the terminal. This is just used in manufacturing. I’ll go ahead and cut it off. I’ll place the terminal on the black wire,
and crimp it in place.To install the cord, first, I’ll need to strip back the red wire
from the router motor that we cut earlier. I’ll strip this back about three-eighths of
an inch. Now, I’ll thread the black wire from the cord
behind this metal brace. I’ll go ahead and reinstall the ground wire
with the screw, and I’ll bring the white cord wire together with the red wire from the motor. Twist the wires together, trim them flush,
and secure them with a new crimping cap.Now, place the strain reliever in the hollow within
the casting, and reinstall the cord clamp. As I install the cord clamp, I want to make
sure that I have some of the outer insulation on the cord beneath the clamp. I have a new cable tie that I’ll use to secure
the black and red wires to the metal post. Now, reconnect the wires to the switch. First, the black wire and then the red.Now,
I can reattach the cap, and I’ll secure it with the screws. That’s all it takes to install a new strain
reliever on your power tool.Advertisement: Be sure to check back often for new videos
and expert advice. If you found this video helpful, give us a
thumbs up, and leave a comment.

1 comment on “Porter Cable Router Repair – Replacing the Strain Reliever (Porter Cable Part # 901266)

  1. Gary Edwards Post author

    My strain relief replacement came today and took 10 or 15 minutes to install – not counting the trip to the auto parts store for 18 ga. closed end crimp splices. I could have sworn I had some. My Porter-Cable 6902 was older than the one in the video (toggle switch, not a rocker) and there was not as much service loop yardage so I didn't cut the connectors off. Instead, I used a utility knife to carve the plastic cover off and squeezed the crimped ferrule the other way to make it round again so it would slip off the conductors. No loss of wire length that way. Thanks for the quick delivery and a reasonably priced part.


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