It was a hot Tuesday in July. I was in my garage to finish a cedar bird house for my neighbor. I went to turn on my DeWalt DWE6423, but nothing happened. No hum. No shake. Just the sound of my own annoyed sigh.
If your DeWalt orbital sander stopped working, I know that sinking feeling. You have a project to finish, and your main tool is acting like a paper weight. After years of fixing my own gear, I’ve learned that these yellow tools are tough. Usually, the fix is much simpler than you think.
Why Your DeWalt Sander Might Be Dead
When a tool stops, we often fear the motor is fried. In my shop, that is rarely the case. Most of the time, it is a small part that costs five dollars. I took my sander to my bench and opened it up to look for clues.
The smell of burnt toast is a bad sign, but my tool smelled fine. It just would not kick over when I flipped the switch. Here is a breakdown of what usually goes wrong based on my own trial and error.
The Three Most Common Fixes
| Problem Part | Ease of Fix | Cost of Part | Time Needed |
| Carbon Brushes | Very Easy | $5 – $10 | 10 Minutes |
| Power Switch | Easy | $12 – $15 | 15 Minutes |
| Power Cord | Moderate | $15 – $20 | 20 Minutes |
Dealing with Worn Carbon Brushes
This is the classic fix for any pro tool. Inside your sander, two small blocks of carbon touch the motor. They wear down as you use the tool over time. It is just like the brake pads on your car.
One day, I was sanding a large oak table. My sander started to spark a lot through the vents. Then it just quit on me. I unscrewed the top cap and pulled the brushes out. They were tiny nubs.
How to Check the Brushes
First, make sure the tool is unplugged from the wall. I can not say that enough for your safety! You just need a T15 driver for most DeWalt models. Pop the top plastic cover off to see the motor.
You will see two brass clips that hold the brushes. Carefully lift the spring and slide the brush out. If it looks crumbled or very short, you found your problem. I always keep a spare set in my drawer now.
The Sneaky Power Switch Problem
Sanders make a lot of fine dust. Even with a good vacuum, grit gets everywhere. It loves to hide inside your power switch. This can stop the flow of power to the motor.
I remember a project last fall where my sander acted up. It would only turn on if I held the switch just right. It was driving me crazy. I felt like I was doing a magic trick just to sand a board.
Cleaning vs Replacing the Switch
Sometimes, you can save the switch with a quick clean. I use a can of air to blow out the dust. I also use a bit of contact cleaner. It smells like a nail salon for a minute, but it works wonders.
If the switch feels mushy when you click it, the spring is likely gone. In that case, just buy a new one online. DeWalt switches are easy to swap. They usually just have four wires that push into place.
Inspecting the Power Cord
We are all guilty of it at some point. We pull the sander by the cord to reach a far corner. Or we wrap the cord tight around the tool when we are done. Over time, the wires inside the rubber will snap.
The break usually happens right where the cord enters the handle. This is called the strain relief. If your sander works for a second when you wiggle the cord, this is the issue. You can fix this with basic wire strippers.
How I Fix a Broken Cord
I do not like buying a whole new cord if I can avoid it. I usually cut the cord a few inches back from the break. Then, I strip the wires and reconnect them inside the tool.
It makes the cord a tiny bit shorter, but it works like new. It feels great to save twenty bucks with just a pair of pliers. This simple fix has saved me many trips to the repair shop.
Bearing Failure and Strange Noises
Does your sander sound like a jet engine taking off? Or does it scream when you push down on the wood? That is a bearing issue. Inside the sander, small metal balls let the motor spin fast.
If dust gets in there, they get hot and seize up. I once ignored a loud bearing for a whole week. Eventually, the sander got so hot I could not hold it. Heat is the main killer of power tools.
Testing the Bearings
With the sander unplugged, spin the pad with your hand. It should spin smoothly and quietly. If it feels gritty or makes a clicking sound, the bottom bearing is shot.
Changing a bearing is a bit harder for a beginner. You might need a small puller tool to get it off the shaft. But for a high end DeWalt, it is worth the extra effort. New bearings make the tool feel brand new.
Troubleshooting Your Sander: A Quick Guide
| What You See/Hear | The Likely Culprit | My Suggested Action |
| No sound at all | Fuse, Cord, or Switch | Check the outlet and cord first. |
| Large sparks inside | Carbon Brushes | Replace brushes right away. |
| High pitched scream | Motor Bearings | Clean or replace the bearings. |
| Slow spinning pad | Pad or Belt | Check if the rubber pad is dragging. |
Keeping Your Sander Alive Longer
After fixing my DeWalt three times, I learned how to stop it from breaking. Now, my tools last twice as long. Here are my personal tips for a healthy sander that will last for years.
Use a Vacuum Attachment
Dust is the number one enemy of your tools. It clogs switches and kills bearings fast. I always hook my sander up to my shop vac. Not only does it keep my lungs clean, but it keeps the motor cool.
Don’t Push Too Hard
I used to lean on my sander to make it work faster. All that does is heat up the motor and wear out the pad. Let the grit of the paper do the work for you. Your arms and your sander will thank you.
Blow It Out Weekly
Every Friday, I take my air hose and blow out all my tools. I stick the nozzle into the vents of the sander and let the dust fly. You would be shocked at how much dirt comes out of there. It takes ten seconds to save a tool.
Final Thoughts on DIY Tool Repair
Fixing a DeWalt orbital sander stopped working is a great way to build your skills. It is empowering to know how your tools work inside and out. Plus, you get back to your wood shop much faster.
I hope this guide helps you get your sander spinning again. There is nothing like the feeling of a tool roaring back to life. Now, go get that project finished and enjoy your clean wood surfaces.
FAQs:
Why did my DeWalt orbital sander suddenly stop working?
It is likely worn carbon brushes or a clogged power switch. Dust buildup often blocks the electrical flow. Check your power cord for any visible wire breaks too.
How do I know if my sander brushes are worn out?
Open the motor case and look at the small carbon blocks. If they are shorter than 1/4 inch, they cannot touch the motor. Replace them to get your power back fast.
Can I fix a DeWalt sander switch that feels stuck?
Yes, you can often blow out the dust with compressed air. If it still feels mushy, a new switch is a cheap and easy fix. This keeps your tool safe and reliable.
Why does my orbital sander smell like it is burning?
This smell usually means the motor is working too hard or the brushes are sparking. Stop using it right away to avoid permanent heat damage. Clean the vents to help it stay cool.