changing the base from fixed to plunge feels gritty and the springs don't retract smoothly.

Diagnosis

The "gritty" sensation during the transition from fixed to plunge mode on the DCW600B is caused by the accumulation of fine particulate matter—specifically hardwood dust and resin—within the dual steel guide posts and the internal spring housings. Because this router is often used for edge-forming and trimming, the vacuum system often misses the plunge mechanism, allowing sawdust to mix with the factory lubricant. This creates a thick, abrasive paste that increases friction and prevents the springs from returning the motor to the top position smoothly. You can confirm this by observing the plunge action: if the motor "stutters" or hangs up at a specific point in the travel, or if you see a brownish-grey sludge clinging to the chrome posts, the issue is contamination. If the grit is felt specifically when toggling the base lock lever, the debris has likely migrated into the locking pin channel, preventing the mechanism from sliding freely between the fixed and plunge settings.

How to Fix It

To restore smooth operation, you must perform a deep clean of the plunge assembly. Follow these steps precisely:

1. Power down the tool and remove the battery pack to ensure safety.
2. Release the base lock lever and slide the motor unit completely upward to expose the full length of the two chrome guide posts.
3. Use a stiff nylon brush or compressed air to blow out the large chunks of debris from the plastic bushings and the spring cavities located at the bottom of the base.
4. Dampen a lint-free microfiber cloth with isopropyl alcohol and wipe down the entire length of the steel posts, removing all old grease and resin buildup until the chrome is bright.
5. Reach into the plunge bushings with a cotton swab dipped in alcohol to clear out the internal walls of the sliders.
6. Apply a light coating of a dry-film lubricant, such as a PTFE (Teflon) spray or a dry graphite lubricant. Spray the lubricant onto a rag first, then wipe it onto the posts to avoid overspray getting into the motor vents.
7. Cycle the plunge mechanism up and down 10-15 times to distribute the lubricant evenly across the bushings.
8. Toggle the base lock lever back and forth several times to ensure the locking pin is seating correctly without resistance.

If That Didn't Work

• Check for "burrs" or nicks on the chrome posts. If the router was dropped or hit, a small dent in the steel can create a snag point. Use 1000-grit wet/dry sandpaper with a drop of oil to lightly polish out any surface imperfections on the posts.
• Inspect the plunge springs for deformation. Remove the base assembly and check if the springs are seated squarely in their cups. If a spring has buckled or lost its tension (evidenced by the motor not returning to the top position), you will need to replace the spring set.
• Examine the base lock lever for a cracked plastic housing. If the lever feels "mushy" rather than gritty, the internal plastic guide may have worn down, causing the locking pin to tilt and bind against the post.
• Verify that the collet nut is not over-tightened or protruding in a way that it is rubbing against the interior of the plunge base during travel, which can mimic the feeling of gritty springs.

Heads Up

• Never use WD-40, automotive grease, or heavy machine oil on the plunge posts; these are "wet" lubricants that act as magnets for sawdust, which will accelerate the grit buildup and eventually seize the mechanism.
• Always blow out the plunge assembly with compressed air after every project, regardless of whether you used a vacuum, to prevent resin from hardening in the bushings.
• Ensure the base lock lever is fully engaged before starting a cut in fixed mode; a partially engaged lock can cause vibration that wears down the guide posts prematurely.
• Check the tightness of the base mounting screws every few months, as vibration can loosen the assembly and cause the posts to misalign, leading to uneven friction.