DeWalt 20v Chainsaw Oil Leak Fix (It's NOT the "missing" O-Ring)!!

Teardown, inspection, repair of a DeWalt 20v DCCS620 chainsaw for the notorious bar oil leak. This video shows what is actually going on with my saw. The "missing o-ring" videos are not the solution as shown in my video, at least for my saw anyway. The 60v saws and pole saws may have the same issue, but I don't have ones to tear down.
You might as well add some extra silicone grease in the gearbox while you're in there.
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Chain Sharpeners: amzn.to/3Ypg4yl
Chainsaw Soft Case: amzn.to/3YduPE3
Chain Cover: amzn.to/3tXwL9d

[@harozrock1]

Just did this! Used the black RTV. It was delivered today and i did it right away before putting oil in. Thanks for the guidance! To whoever is reading this, this job is easy if you pay attention and follow his guidance. Definitely worth it.

[@peppermoongarage]

I'm glad it worked out for you. It's a cheap and relatively easy fix.

[@harozrock1]

@Pepper Moon Garage Indeed it is sir. Thanks again.

[@Douginont]

I just did the same thing yesterday. I had some issues with the o ring at the cap. It was dry and popped out. A little mineral oil and it seems to have done the trick.

[@hjohn8246]

This is an amazing video. I did the work before putting any oil. Could not have done it without this video. Superb effort - thank you.

[@peppermoongarage]

Thanks for the feedback!

[@JaredBusch]

YES, IT WORKED!!!!! I can't thank you enough. While these shouldn't leak at all, it's a great little chainsaw and with having other dewalt tools, I wanted to try this so I didn't hate it so much. I've tried the silly extra O ring mod others "claim" fixes the leak, (not sure how, but ok), and yeah it kept leaking. Had a hunch that the molding parts were an issue but wasn't confident enough to take everything apart. Following this VERY WELL MADE tutorial made is soooo easy. Disassembly and reassembly is only time consuming, not hard. Anyways, I threw on some blue gasket maker on all the bits shown in the video, though I applied a bit more on the outside of those bits once I installed them back into the tank, just for good measure. Filled up the tank, waited overnight, checked today and not a single drop came out. So much for everyone saying "all chanisaws leak".... well this one shouldn't, it's just poor manufacturing. Now it doesn't leak at all. Good grief, what a mess this thing used to create. bottle of bar oil will last forever now, lol! Great video and thanks again!

[@peppermoongarage]

That's Awesome and great to hear! I didn't see this fix in any other vids so I made this one. I really like this saw, but the leaking was a big PITA. Mine hasn't leaked since I did this. Thank you for your comment, it made my day!

[@wolfdogg5150]

I was hesitant to buy this saw at first because of the leaking oil complaints but luckily I found this video and decided to pull the trigger on the saw. I went ahead and followed this easy fix before I put any oil in it and haven't had any leak issues. lt s a nice, light duty saw that is extremely convenient when you don't feel like dragging the gas saw out. Great job on this video, I highly recommend anyone who buys this saw watch this video and go ahead and nip the oil leaking issues in the bud from the start.

[@peppermoongarage]

Nice job proactively preventing the leak. I agree that they are a great light duty saw. It won't replace a gas saw for larger jobs. I find it super handy to take camping and cut smaller rounds for firewood.

[@craigkincaid1568]

After experiencing the leak on my brand new saw and having seen your video I chose to send it in for warranty repair hoping enough time had passed that Dewalt would fix it. They sent it back just as it was and said that " The oil leak was designed into the system to make sure bar was oiled all the time😂 Came back covered in residual oil I couldn't get out of tank during Shipping..

[@srt8speed]

Seriously?!?! Designed an oil leak so the bar would stay oiled?!? That’s INSANE!!!

[@scarletbegonia5150]

Just did this last night. Worked like a charm! thanks! the oil leak was getting worse and worse as time went on. Loved the saw but have to carry it around in a bag because it would dump half a tank of oil in my car by the time i got to where i needed to be. No more leaking at all. Left it over night.

[@peppermoongarage]

Nicely done!

[@atrainace114]

It's good to see someone that knows how to correctly reinstall screws into plastic. Bravo my good man awesome vid.

[@peppermoongarage]

Exactly! Thanks for noticing that tip - thanks for watching!

[@ericst-georges7806]

Thank you for taking the time to make this video! I followed this step by step, put it all back together and it WORKED! 🙏👌

[@peppermoongarage]

Woohoo! Good to hear.

[@tombelanger5489]

Thanks for taking the time to produce the video!

[@Cianan-vw1lb]

Thank you for the breakdown and fix. Great little saw. I've had mine sitting on paper towels on a mat.

[@user-lz4co9gs7j]

Amazing video! I have the older DeWalt 40v, DCCS690 and it's been leaking for years and I just accepted it. I found this video, bought the black RTV and did this fix last week. The DCCS690 is essentially the same process with some small differences. Your video gave me the confidence to fix this myself. The hardest part was getting the years of debris cleared out as I've never given in a proper clean (in over 6 years ha). I also discovered I need a better air compressor... anyhow, THANKS for taking your time to share your expertise. It's been about a week and I now have zero oil leaks.,

[@peppermoongarage]

I'm glad you finally got yours to quit leaking. Thanks for confirming the 40v saw is similar.

[@karlkrebs1035]

I was looking for a video of the breakdown/disassembly for this exact reason! I found this the perfect reference video and followed your instructions. So far the leak is resolved! Thanks for the content!

[@peppermoongarage]

Awesome, I 'm glad you found this helpful. There are a lot of misleading fixes out there. Thanks for the feedback.

[@chriskemp6941]

Thanks for the video it was very helpful. I also found that the O-ring at the end of the oil feed to the bar was too small. The white plastic piece that pushes into the case for the oil feed was so loose it just fell out. This means when the oil is being pumped a lot of it goes straight into the casing. A bigger O-ring provided a nice snug fit and no more oil coming out the case bottom after use.

[@peppermoongarage]

That's a good thing to keep an eye out for when you're in there. Nice fix!

[@hyvemynd605]

subscribed. this is the most comprehensive and detailed fix ive ever used on youtube. One commentor said you can leave the brake spring assembly on, and he is right. I took the left hand threaded nut off the sprocket, pulled the brake pin, and left everything else in. Thanks for this video man. Truly is a massive help for the community.

[@peppermoongarage]

Thank you, I appreciate the positive feedback.

[@nathanbates7980]

Just got mine in the other day. This is the first thing I did to it right after it came out of the box. Never going to be more oil free for creating a good seal on the tank and adapter was my thought process. Went with the Ultra Black. Looking forward to having this saw as my trim saw to supplement the main gas saw. Thanks for the vid.

[@peppermoongarage]

Good planning. Yes, these are good saws for small stuff, but don't replace a gas saw for larger stuff. Thanks for watching.

[@joeberry517]

I just did the same. I didn't want to take the chance that it might leak and have to clean the oil out so I did it before any oil touched it. And I didn't have any parts or screws left over thanks to your detail and good filming. Thanks!

[@AA-fg3wj]

Ok, I did this hack on my brand new DeWalt 12" 20 volt saw. The only leak was at the oil cap. I installed an o ring on the recessed area of the cap. It has held bar oil for two days now and not leaked. Thanks for this video, it prevented a problem before it started!

[@peppermoongarage]

Nice!

[@tomvandervoort2437]

Thanks for the great fix. I complained to DeWalt, got the same, “empty the tank after use” B.S. After some back and forth discussion, they sent me a brand new one! Both are getting this fix.. sad that they come faulty from the factory. All my other DeWalt tools have been awesome but on this saw, they need to do better.

[@fullchrist4405]

Qui a fait ça? Dewalt ou le vendeur? Et dans quel pays tu es pour info?

[@simonbaker9983]

Brilliant video many thanks! Followed it to the letter and no leaks. So simple to do with your help, many thanks! Sadly Dewalt still haven’t changed the tank design on the DCM565N here in the UK, but thanks to you we can adapt and overcome!

[@peppermoongarage]

Nicely done, my friend!

[@nunyabusiness7405]

after 2 weeks of doing this fix, and keeping it totally full of oil and sitting... zero leaks. the only dribble i had is now from the oiler nipple with the thicker oring to seal inside the clamshell half for the chain oiler, all because i spun the chain by hand lol thanks again for showing the fix, now i love my lil dewalt limber.

[@peppermoongarage]

Nicely done!

[@giovannimonteferrante79]

That is it!!! I struggled with that leaky saw for 2 years, tried the Oring fix... nada. Did this and that was the end of the leak!. Thanks so much for posting this, along with the step by step instructions for those of us not necessarily mechanically minded!

[@peppermoongarage]

Nice work!

[@Ian-G-Johnson]

I just got thos saw last week... I'm excited to tey this fix out when i get the time! Thanks for sharing

[@joeogden243]

Thanks for the great video. I was ready to chuck my leaking saw in the trash. you were exactly right on the filler neck to oil tank being the culprit

[@peppermoongarage]

Excellent, glad you got it fixed. Thanks for reporting back.

[@JD-ft2lr]

Thanks for this video tutorial! Was easy to follow. Turns out my saw's primary leak was most likely the small o-ring on the plastic fitting that slips into the casing (oil port for the chain). The o-ring was smashed off to the side and deformed. Got a new one at the local Ace. Fittings at the tank looked okay but I sealed em anyway using RTV. Took the gear case cover off as someone suggested and redistributed the grease. Appeared to be some sort of graphite grease and was heavy in some places and absent in others. I'm sticking with the original bar and chain until the chain wears out then will upgrade. Thanks again!

[@gs1100ed]

Where is the gear case cover?

[@ralphvigil6634]

Awesome video. I couldn’t have done the job without it. Thank you.

[@pierrec9287]

Thank you my good sir. I just bought mine and immediately tackled this. now just waiting for RTV to dry!

[@peppermoongarage]

Nice!

[@MrHemi4spd]

Thought mine was missing an o-ring untill I saw this. Thank you ill have to do this myself. Damn rhing leaks like a sieve

[@grillinrich9205]

It's been a few months since I got a Dewalt 20 V chainsaw and I tore the saw down and fixed the leaks before they started leaking. Since then when I use the saw if I place the saw down on the ground (bottom down) there is a small puddle of oil under it after sitting for 10-15 minutes under the chain drive spocket area . I believe that it's due to the over aggressive oiling system because this thing goes through a lot of oil for the cutting that I do. I used to own and use a Sthil 044 with a 2' bar back when I was logging and that saw didn't use half as much oil. So when I store the saw I have it in position with the bar down, cover on at the 6 o' clock position and then there is no oil to clean up 🙂.

[@raywakila7153]

Thanks a lot for this video! Very thorough and best of all, it worked! Had a few rough spots - getting the whole safety bar apparatus back correctly in place was difficult for me but I finally got it back together. Now I feel like I have the chainsaw Dewalt should have made in the first place. Anyway, great job!

[@peppermoongarage]

Nicely done! Thanks for the positive comment.

[@BigRedServicesLLC]

This is great info! I have similar leak on mine I wasn’t able to get it all off I must’ve missed a screw, will try again.

[@srt8speed]

I admire you for tearing the saw down and fixing it properly! I just know myself enough that something would not go back together right and I’d be worse off 😂… Think I’ll just keep it in a case with shop towels.. I’m a beaten man!

[@peppermoongarage]

It's always good to know your limits! I noticed the SRT8 in your name. I have a big turbo SRT4-Neon.

[@delektrik1]

I just stand mine up on the battery with the bar pointing upwards and let gravity prevent it leaking. Seems to work!

[@notquitea]

Same, but after watching this video, I'm wondering if most of the leaking oil is just staying inside the case.

[@apaulosmith5653]

Or you could just drain it after every use like some morons suggest

[@marynagy8072]

I store it on its side, oil cap up, with very little oil in it. Then you avoid all the areas noted in the video where it might leak. Stays dry. Also don’t have to totally drain it, if you put only a little oil in and use what you need for the job.

[@firstlast-qo8pv]

@@marynagy8072 Same here, I found storing it on it's side (on a piece of cardboard, usually from an Amazon shipping box) there might be some residual drips, which the cardboard catches.

[@evoredline]

Finally somebody who knows it not the “missing O ring”! I also had an RX8, I guess that’s why we are able to problem solve so well. I fixed mine by too but it developed the leak after use again. I will try the sealant this time and it should stay fixed I would assume. Seems like the adapter seal loosening with use and the sealant will prevent. I’ll let you know how it goes. Thanks for the great video!

[@peppermoongarage]

Thank you. As an RX8 guy, you may know how great the Hylomar is. It should stay pliable in the presence of the bar oil and still hold a seal. I also considered filing down the rough parting line, but that may cause more problems than it solves. No leaking so far other than off the bar&chain. DeWalt really over-lubes their bars.

[@TheReal1953]

@@peppermoongarage I would gently file down the mold seams....that's a real factory screw-up..cheaply made and fit. As easy as plastic is to file, might even try a stone just to make sure it goes slowly.

[@dwellner502]

@@TheReal1953 what would be the benefit of filing down the mold seam? Is this an aesthetic thing?

[@TheReal1953]

@@dwellner502 Anywhere the surface isn't exactly smooth, you'd want to file or stone to flat. The surface should be like a table top.....then you don't sweat the gasket or sealer.

[@TheDirtyBirchTrails]

OMG as if, I had an RX8 too. And my garage is loaded with yellow tools including the above leaking chainsaw LMFAO

[@bernardfortin8349]

Just did this fix with the suggested sealant, really thank you

[@peppermoongarage]

Great to hear! Congrats!

[@MIHomesteading]

Thank you for the great video! I just bought the saw & this will be done before I oil or use it!

[@peppermoongarage]

Nice, thanks for watching

[@dlkline27]

Great instructional video. I'd like to give it five thumbs up instead of one.

[@peppermoongarage]

Thank you!

[@justinmather8232]

Great Video, I was able follow it easily. My saw now leaks less, but does still leak around the filler cap. The factory O ring is present and looks fine. The cap itself has a broken wing on the bottom, so it only engages 1 of the locking lugs. Have a new cap on order, so hopefully that fixes it. Extremely disappointed that the saw leaks so badly. Neither of my Stihls leak much, and certainly not from around the fill cap.

[@peppermoongarage]

Thank you for the comment. Those "wings" on the cap actually compress the cap against that inner square O ring that the sealant goes on. A new cap should help out. Please let us know if it helps or not.

[@justinmather8232]

You were correct, of course. With the new cap installed, there's zero leaking after a day of sitting with a full oil tank. The replacement cap seems a little more snug, or tighter locking than I remember the original ever being, but I'm not sure how long it was broken. Thanks again. for the great video!

[@peppermoongarage]

Nice!

[@grillinrich9205]

I got one a week a half ago and tore it down before it saw any oil. I went with the ultra black, resealed the vent, supply tube and the filler tube reassembled it and never got a drop 💧 of oil out of it. I know it's only a 10 1/2" cut but I was cutting 12" trees NO PROBLEM. Thanks again for the video it was very instrumental in tearing it down and reassembly 👌👍🤜🤛🤙

[@peppermoongarage]

Nicely done!

[@FormerlyKnownAsAndrew]

Thank you. I don't own this saw (yet) but I will do this if I ever get one.

[@alexparacsi8573]

I wrapped some white plumbing tape around the screw-in cap. It worked.

[@colins2135]

Thanks for sharing! Great job!

[@peppermoongarage]

Thanks for watching! I just used it for firewood on a hunting trip and it's super handy to have in the truck.

[@jimsandall2073]

Thanks for the video. Got my saw 3 weeks ago, filled the bar oil and within 12 hours the whole tank of oil leaked out around the front handle under the tank. Did your fix with RTV silicon which solved the issue. Now we need a way to regulate the oiler, I've never seen a saw puke so much oil from the oil system. I can hold the saw over a log and turn it black from the bar oil spray off the bar not to mention the oil slick running out the chain cover.

[@peppermoongarage]

Mine over oils a bit IMHO, but not as bad as you are describing. What type of bar oil are you using?

[@jimsandall2073]

@@peppermoongarage A thicker Stihl oil, not sure of the name, which has helped with oiler leak in my gas saws during summer months. My Echo leaked excessively until I switched to the Stihl oil.

[@peppermoongarage]

OK, you should be good with a name brand oil that is actually bar oil like you mentioned. Sometimes people run regular motor oil, new or used, and that could make bar oil consumption greater. Post back if you discover a way to regulate the bar oil flow.

[@rigpigman0]

Great info, well done!

[@peppermoongarage]

Thank you, sir

[@AgeOrmstad]

Realy informativ and good job 💪

[@peppermoongarage]

Thank you

[@Lumberhacksteve]

LMAO... If I pulled it apart like that it would never go back together. Great video and now I am dreading doing mine but I guess I will need to in order to fix it. Thanks for the video Excellent job.

[@peppermoongarage]

lol, go for it!

[@rcjarvis]

Hi, I fortunately watched your video before buying... I almost turned away from Dewalt but I have a lot of Dewalt 5ah batteries, so I kept coming back to this one since my friend has 4 other brands of electric and they all leak... SO I hade the pleasur of doing mine with you and this video on brand spankin newone, no oily gunk or oily wood residue... Thnaks a lot, apart from re inserting the huge black spring, it all was easy and I hope to see this chainsaw clean enough to carry around without bagging it...

[@peppermoongarage]

Thank you. I'm glad the video helped. It's a fairly simple fix. Like you mention, the investment is in the battery/chargers so it's ideal to stay with the same system. I now have the DeWalt 3/8 impact, inflator/compressor, chainsaw, string trimmer, hammer drill/driver all using the same 2 chargers and 4 batteries.

[@rcjarvis]

@@peppermoongarage what shrpener do you use for the blade? I wonder if the Stihl 2 in 1 sharpener works with the dewalt chain size ?

[@peppermoongarage]

I use an electric sharpener that has a disc. I have seen that the 5/32 file size should work. I'm not sure what size the Stihl sharpener is.

[@rcjarvis]

@@peppermoongarage the Stihl 2 in 1 also sharpens the guide notch... important or else the guide remains higher than the blade (shortened by filing) and keeps the blade flying over the wood instead of biting in it... a few good videos on the subject on YT...

[@lostagain2992]

That’s great! I’ll just keep an absorbent mat in the bottom of my chainsaw box. That little saw rocks for what it is!

[@peppermoongarage]

I agree, they are great. It won't replace my Husqvarna 55, but it's handy for smaller jobs and camp firewood.

[@lostagain2992]

@@peppermoongarage My Farm Boss does it for me😉👍

[@MHzTweaker]

I just finished this process and it took way longer than it should have, probably because I am cautious and take time to clean and examine everything. Here are some things I found. I don't see how these tanks could NOT leak. There is such a gap where the tank seam is at the filling port hole. I treated the other openings with Hylomar as well. I took everything apart, blew all the crud out with an air compressor and de-greased with GUNK and cleaned the tank and tubes with water after de-greasing. I left nothing to chance concerning whether or not I am going to get a good seal this time around. Absolutely the most aggravating thing about this entire process was getting that brake spring back in place and under compression. OMG, I about lost it a few times....and I take things apart for a living. I did take the cover off the transmission and move a bit of that grease on to the gears. I took a lot of photos and had all my parts laid out on a clean work surface with a disposable white 36" x 32" pad on top to absorb oil etc. In my particular saw, it has leaked from day 1 and I've owned it for 4 to 5 years now. Hopefully this gives me some relief from that nightmare. I purchased a DeWalt 28" plastic toolbox to keep it in and lined the bottom with towels. Another thing I noticed was that the little port that attaches on the outside of the tank to two prongs, also has an "O" ring on it. Mine was mashed flat and not doing anything to make a seal. I replaced from a new box of "O" rings I just bought. There are 2 flexible tube in there. One is before the pump, going into the tank. The other one is after the pump and mating to the port feeding oil to the chain. The tube on the tank side was getting a bit stretched so I trimmed a 1/4 inch of the stretched tubing off for a tighter fit. Since my saw has some age, I assume this will happen to all these eventually. Maybe some auto grade rubber line can be used if I ever have to go back in there for any reason. One thing I did do was remove that 2nd "O" ring on the fill port that many said solved the problem. The downside to adding that 2nd ring was that it add more material into the cap seal/opening interface. What it has done is start to warp the two hooks on the fill plug itself. I'm going to buy an extra one from Amazon now that my plug is deformed. I will update when I know if this solves my leaking issues.

[@peppermoongarage]

I originally tried that "missing O-ring" as well and my oil cap splayed out as you described. It's holding in there for now, but I'll probably end up replacing it at some point.

[@clarrisalee1660]

So did it work?!?!

[@MHzTweaker]

@@clarrisalee1660 Yes, so far so good. No leaks inside the DeWalt toolbox I store it in. I lined it with paper towels to absorb leaks but there are none. I call this fix a SUCCESS.

[@raywakila7153]

Ditto on the chain spring, dude, that damn thing nearly made me give up on it

[@kentduggan8626]

I will just deal with the tiny leak, this little saw is a damn animal, capable of any size job even cutting a notch to fit the saw in lol, the real key is keeping that chain super sharp

[@marynagy8072]

I put very little oil in it, less than half, and store it laying on its side with oil cap up, and it does not leak at all. I would never try this. It would completely spoil the manufacturer’s warantee and I highly doubt I could follow these directions as accurately as necessary to make this new machine function again. Thanks for examining everything.

[@Digital_Dairy]

Going through DeWalts warranty was a pain, I would count more on a self fix than that, sadly.

[@frede7410]

thank you, you made it much easier .

[@peppermoongarage]

Glad to hear that!

[@mikerosie5861]

Yep it works never had leak with mine did this as soon as I got it

[@CharlesReed-bj4uk]

Open the gearbox while you have the saw apart. The gears inside are bone dry. There is a little dab of grease tucked in the corner where it will not touch the gears. I greased them myself. Without lube they'll wear out quickly. Good video. It helped me re-assemble the chain break. Oh...no leaks now. Thanks

[@peppermoongarage]

Thanks for the tip.

[@grillinrich9205]

@@peppermoongarage Thanks for the tips guys. I am in the market for a new chainsaw and I'll fix it and won't have any problems 👍👍

[@tooolboxx]

Great video, but I doubt that I will bother. For as much as I use the saw, it just isn't worth it. And I really wasn't surprised that it leaked; every chain saw I have ever used has leaked. Btw, I like your camera.

[@peppermoongarage]

For sure. You can always drain the oil, or just not fill it above the leak point, which is what I did before fixing it.

[@danielkeith8670]

Excellent excellent video I just fixed my saw

[@peppermoongarage]

Congrats, Nicely Done!

[@phil9171]

very comprehensive repair.

[@peppermoongarage]

Thank you

[@Pete_R63]

I have one that I want to use but I can't get the cap to the oil reservoir to open. It won't turn to the unlock position and I am worried that I will put a little too much muscle into it and end up breaking the cap.

[@jerrygreer5715]

You need to send your video to DeWalt. If you don't, I will. I just ordered one of those saws and every review said they leaked oil. But they said every brand leaked oil so I ordered it anyway. I hate to take apart a brand new saw to fix this problem but I may have to if DeWalt has not fixed the problem already. Thanks for the video!!!! I saved it so I can put everything back together after the tear down. Have a good one.

[@jerrygreer5715]

By the way, I just emailed your video to DeWalt. I asked them why they can not do this at the factory.

[@peppermoongarage]

@@jerrygreer5715 Nice! Let us know if they respond.

[@jerrygreer5715]

I will, nothing yet. Great video. I should be getting mine in a couple of days. I am going to put oil in it first to see if they have fixed their problem before I take all apart.

[@clarrisalee1660]

Following this thread…

[@jerrygreer5715]

@@clarrisalee1660 I have now used my chainsaw and it did not leak oil. They must have fixed their problem!!!

[@jeremyduncan8030]

Great video. I'll try it with mine as well.

[@peppermoongarage]

Good luck, it's actually pretty simple.

[@jonnyphenomenon]

Pro Tip: it can be hard to find Hylomar blue in a lot of places. In the UK they use hylomar like a comma, but here in the US, (Maine anyway) its not available. The good news is that Permatex makes the stuff too, but they call it "Permatex Permashield Gasket Dressing 85420" - its oil and fuel resistant, comes in an orange tube, available at any auto parts place. Also, be careful when you screw the cap back on the tube. I don't know if the compound breaks down the plastic of the cap or what, either way, leave it loose or it will crack and the stuff will dry out.

[@peppermoongarage]

Good tips, thanks

[@RectanerTreadway]

“Seth Rogen goes exploring in power tools” 😆jk Thanks for taking the plunge 👍

[@peppermoongarage]

Lol!

[@MrRustydawg]

Great video. I took the two back I bought and got a Makita. Sure I’m capable to do the fix but why should I need to? I even called Dewalt and they told me it’s normal and I should drain the oil out after use ! No plan for a redesign as it was designed that way!

[@peppermoongarage]

I agree, this should not need to be fixed - DeWalt should have better quality control. Draining the oil out is not a good solution. I'm already invested in the 20v DeWalt battery system, so I really wanted to get a solution to this leak. My saw is still not leaking after this fix.

[@Grahams-Grass]

Nice. Looking at getting one but heard about the oil leaking ... Good to know there's a fix👌.. although you would think this should be covered by the warranty 🤷 come on dewalt

[@peppermoongarage]

DeWalt dropped the ball with this. This is a design issue - guaranteed to leak. A warranty repair would install the same poorly designed parts and most likely still have the issue. They hide behind the "drain the tank" in the manual.

[@BA-zy2kb]

Great tear down reference video. The internals look very similar to the 1st Gen 16” flexvolt chainsaw. Probably not surprising. Both my 12” and 16” leak while stored. The additional o ring solution did not work for me either. Thanks for sharing perhaps I give this a try in the future. Cheers from 🇨🇦

[@peppermoongarage]

Thanks for the comment. I didn't see any other videos that described this source of the bar oil leak. It's a pretty simple fix.

[@UEDSquadron]

do you fixed you flexvolt ? is it works ?

[@BA-zy2kb]

@@UEDSquadron nope both saws still leak but I haven’t tried paper moon’s solution yet. My 1st gen 16” also stopped pumping bar oil. I replaced the pump (that’s how I learned there are two different 16” versions) but it has weak flow.

[@BA-zy2kb]

To change the pump I had to take it apart. I wish I had this video as a reference as the two are very similar.

[@oldcaliforniakid]

I just used this breakdown, not for the leaks, but just to understand the breakdown process and reassembly of the parts. I wasn’t getting any chain oil to the chain (I bought this from someone who used it once and put it on the shelf). The tube running from the oil pump to the bar was all plugged up with a gummy substance (like old linseed oil) and I needed to take the spring out of it and clean it and the tube with a thin wire and some light solvent and then soapy water. Did the whole thing in a couple of hours and have a new chainsaw for very cheap…

[@peppermoongarage]

Nice score with a bit of elbow grease

[@oldcaliforniakid]

Thanks to you! How do I leave a few $ to say thanks?@@peppermoongarage

[@paulmcdonald9257]

Does anyone know why the DewaltR&D team doesn't know about this? It's strange that we are having to improve on the design ourselves. Brilliant video buddy.

[@peppermoongarage]

I'm sure they do know, but choose to not spend the money to manufacture it correctly. It's cheaper to just put a statement in the manual - SMH, FP. At least it's not an expensive fix if a person is comfortable doing it.

[@ama7509]

brand new saw, yet to use or add oil. Given hand tremors & decreasing vision, any options to ship my product to accomplish this service, for a fee? Perhaps you, Pepper Moon? Perhaps Dewalt dealer? I would appreciate any options. Txs.

[@nunyabusiness7405]

just did mine, i could see the imperfections on the square oring that is between the adapter and the molded tank. smoothed the tank lip gently with razor blade, rtv both sides of square oring and reinstalled. i also found the oring to the oiler nipple was not even making contact with the case half so i swapped it for one that seated snug and sealed. no mo reeky reek.

[@peppermoongarage]

Excellent!

[@toxicbear4792]

So it's safe to say it's the bar oil tank reservoir .... It looks to me if the manufacturer didn't put the seem right down the middle where the vent and plug are.. it would never leak...correct?... I Wonder if they make a After market or a original tank that does not have the seem in the middle of the ports.?... Thank you for the video

[@peppermoongarage]

Yes, the parting line is in a bad location. I'm not aware of an aftermarket tank, but that seems like a good idea if someone were to make one. Thanks for watching.

[@caputoskubota337]

Mine has leaked like crazy from day 1. The fact this is normal is beyond me.

[@peppermoongarage]

I agree, it seems like DeWalt missed a quality control opportunity here.

[@MazichMusic]

I have this saw, but have not had a leakage issue. This video may be of use if mine does leak. Great little saw. One suggestion: if you're going to fast forward through steps, I suggest doing a voice-over instead of sounding like Alvin.

[@peppermoongarage]

lol, Good idea. I'll try that next time. Thanks for watching and the feedback.

[@bonniehatcher8198]

Thank you so much! I will be fixing my chainsaw!!!

[@Gordon_L]

Quick question , could the brake spring assembly be left in place if the sprocket drum were removed first ? Thanks , a very good instructional you've done here .

[@peppermoongarage]

That's a good question, I don't have an answer to that. That would make it easier. If anyone knows, please reply. Thanks for watching.

[@alanwilkins249]

Yes. Just did my 16" saw and left complete spring mechanism in. Still have to take long pin and brake handle off to complete separating the two half's but you don't have to take out the rest of the spring assembly. Leave brake handle in the off position (towards handle) before removal to be able to take gear out.

[@crazyethanyeahyeah]

Thanks for the great detailed video ... I just bought this Dewalt chainsaw from my local hardware store on clearance; read the reviews about the oil leak problem, thought I prevent than fix. Could you use alternative sealants? I am from Australia and the Hylomar non setting blue sealant is difficult to source ... I have some Permatex FORM-A-GASKE NO.2 SEALANT - do you think that would work also? Many thanks - Ethan

[@peppermoongarage]

Yes, the No.2 should be fine - it's non-hardening and oil resistant. I used to use that before I started using the Ultra Black which I find to be easier to apply. The Hylomar is great if you can get it (Link in the description), even if it is a bit spendy. Reply back either way and let us know how it works.

[@Walczyk]

What about lightly filing off the parting line irregularities? I love hylomar and my 16” dewalt seeps oil just like this

[@peppermoongarage]

I thought about that but wasn't sure I could get it flat enough. The parting line on my saw is more of a void than a protrusion. If you try it, report back and let us know how it went.

[@allnoyz7895]

I've owned two Husqvarna chainsaws. I love them, but both would leak bar oil if left sitting for a while. I put them in a plastic cement mixer pan from Home depot. Done.

[@peppermoongarage]

That's a good work around if you have the room.

[@qb7384]

Wonder if you can use a heat gun to melt the parting line together?

[@peppermoongarage]

The parting line just creates an uneven surface that requires sealer.

[@andreipiv]

The leaking is starting to annoy me so it's about time to crack into it! If i take apart the gearbox, any suggestions for the grease to put on those gears?

[@peppermoongarage]

Use some silicone based grease which plays well with plastic. I have had a tube of this for years and I use it for a lot of things: amzn.to/3seYb9N

[@krelllab6366]

I REFUSE to fix others massive design mistakes. I went to the local hardware store and purchased an electric STIHL MSA 70 C-B .. it DOES NOT LEAK.

[@nelsonbrum8496]

I bought a toolbox long enough to store my chainsaw in, with a spare bar & chain, 2 extra batteries, & quart of bar oil. I've had mine for a couple yaers now, and keep it in the box with the fill plug down, and haven't had it leak yet. *sgrugs*

[@dustingardiner3301]

I just bought the saw. I wonder if this should be done before I even do use it. I wonder if dewalt finally fixed this problem would you know?

[@peppermoongarage]

I don't know if it's been fixed on the newer saws. Let us know if you find out with yours. They are great if they're not leaking.

[@dustingardiner3301]

Thanks for the quick reply. I might just rip it open before I even add oil into it. Last thing I want is oil going all over my garage floor. Thanks for taking the time to make a vid and show us all how it's done. Much appreciated!

[@rudeman1914]

Should have recall on this!

[@Ragnar009]

A lot of these 40V chainsaws leak bar oil. I have a Worx 40V that amazingly does not.

[@ricc6310]

I just lay mine over on its side, but it has leaked oil sitting upright since new.

[@peppermoongarage]

I did that for a while as well, but it's not always possible in certain situations (camping, hunting, etc.)

[@5-minute-witness356]

there should be something like Fix-A-Flat that you can add to seal it without taking it apart.

[@clarrisalee1660]

Agree! I think if I took mine apart I’d never have it work again 😢

[@stevencross8937]

This is something that DeWalt needs to fix when they build it. I just bought one two weeks ago and they still have this issue.

[@peppermoongarage]

100%, my friend!

[@patterdalezipsuzilil]

All chainsaws leak oil now in the manual you need to remove oil when not in use I have latest 500mm bar 54v version that's there answer to the problem

[@josepalma343]

If I have to work that hard to fix something that costs over 300 just for the tool. I can’t imagine the others green tools!

[@peppermoongarage]

I paid $135 for the tool only in 2020 and they run about $170 now. I do agree that this fix should not need to be done no matter what someone pays. Good point though - this "green" battery tool does leak oil by design (or poor QC), lol.

[@Strutingeagle]

Now question is because we want this chainsaw from DeWalt, Have they fixed the problem so they don't leak now?

[@TrailBoundco]

Did I miss the part about the fix for the cap leak? I saw the rtv on the other little bits

[@peppermoongarage]

Mine was not leaking from the cap. The leak was between the tank and the adapter seal due to the mold parting line.

[@Williamthebrand]

I have the complete opposite problem. My chain and bar oil is clogged. Will not come out.

[@peppermoongarage]

It could be the passages in the bar or going to the bar are plugged with sawdust. It’s also possible that the oil pump is bad.

[@bigmak9636]

In the manual, it says you’re supposed to empty the bar oil tank every time you’re finished using it I think that would be much easier than taking that all apart and try to fix the leaks

[@peppermoongarage]

That’s true, but have you tried emptying the oil tank? It makes a mess and you’ll most likely get sawdust and/or dirt in your oil container along with the drained oil.

[@Mentaculus42]

@@peppermoongarage I just blow the crud off with a can of “compressed gas air” and use a funnel, relatively painless. Use it to clean the filler cap area before filling to keep the crud from falling in. Also blow the crud away from the cooling vents on the motor at each battery change and clean all of the battery contacts at that time. Seems to help with a number of issues. It can also help with cleaning the debris that collects under the cover.

[@majurbludd]

I am going to try this on my milwaukee saw. They both look like the same design really.

[@peppermoongarage]

That sounds like a good idea. Please report back on your findings.

[@stopwar2712]

hint for the lazy. you can just squeeze the oil back into the bottle after work)

[@peppermoongarage]

That's true, and recommended by DeWalt, but it's messy and not that easy. It tends to get sawdust and other gack mixed in the oil when it drains.

[@jodyandmichelle1]

You could easily charge people 50 bucks a saw + return shipping if you wanted to do this as a service. I think you would have a bunch of work sent your way.

[@dalekaechler4872]

Did your over hauling work

[@peppermoongarage]

Yes, it did.

[@dennisjang1440]

the instruction manual says to remove any remaining oil after use - So it's not designed to hold oil when not in use

[@peppermoongarage]

You are correct about the manual. However, draining the oil tank is a very messy operation.

[@millboss1372]

Right away you looked past the first leakage point. The gasket between the oil gallery of the saw and the bar!!!

[@lcdubs7847]

Takes courage to tear into a brand new saw like that. I'm guessing the bulk of the oil is coming from the feeder, just like every other chainsaw I've ever owned.

[@peppermoongarage]

The bar does get over-oiled, IMHO. There is not a way to adjust the oil flow.

[@777gallen]

@@peppermoongarage that’s why I’m here. Trying to find something on it over oiling the bar. Mine uses a full tank in about 10-15 minutes of use. Was considering using a thicker oil than the recommended sae 5w-30. Idk.

[@peppermoongarage]

I run chainsaw bar oil. It's thicker and tackier. It will stay on the chain and work better. The manual says "Use a high quality bar and chain oil for proper chain and bar lubrication. As a temporary substitute, a nondetergent SAE30 weight motor oil can be used." I think that will work much better for you from what your describing.

[@billoneil2719]

Ive got the pole saw and its doing the same thing. You would think that Dewalt could make a better tank...

[@peppermoongarage]

That's good to know and makes sense. It very well could be a similar issue and repair.

[@ricc6310]

A little more care at the factory and this would not be a problem.

[@peppermoongarage]

100%

[@HB-ix9hl]

No I'm not taking it all apart. Scary