when i switch between the two speeds, the lever feels grindy and doesn't always fully engage, sometimes it pops out of gear

Diagnosis

The "grindy" sensation and gear popping in the Makita XFD131 are typically caused by a failure of the shift sleeve to fully seat into the gear planetary assembly. This happens when the internal shift fork—the component that physically pushes the gear selector—becomes slightly bent or when debris (such as metal shavings or construction dust) accumulates in the gear housing, preventing the selector from reaching its full travel distance. When the selector is only partially engaged, the teeth of the high-speed and low-speed gears are not fully locked. As soon as torque is applied via the trigger, the rotational force pushes the selector back toward the center "neutral" position, causing the drill to "pop" out of gear. You can confirm this by attempting to shift while the drill is unloaded; if the lever feels "mushy" or doesn't produce a sharp, metallic click, the internal alignment is compromised.

How to Fix It

To resolve this, you must clear the internal obstruction and ensure the gear selector is seated correctly. Follow these steps precisely:

1. Remove the battery pack and any installed bits to ensure the tool is completely powered down and safe.
2. Hold the drill firmly and rotate the speed selector lever to the middle position (between 1 and 2).
3. While holding the lever in the middle, rapidly trigger the drill for 1-2 seconds. This clears any small debris trapped between the gear teeth and resets the planetary alignment.
4. Slide the lever firmly into Position 1 (Low Speed/High Torque). Apply a positive, decisive push until you feel the internal detent click.
5. Gently pull the trigger. If you hear a high-pitched whining or a clicking sound, the gear is not engaged. Immediately release the trigger and repeat the shift.
6. Repeat the process for Position 2 (High Speed/Low Torque), ensuring the lever is pushed all the way to the stop.
7. If the lever still feels grindy, use a can of compressed air to blow directly into the gap around the shift lever to clear out accumulated drywall dust or sawdust that may be impeding the fork's movement.

If That Didn't Work

• Internal Lubrication Refresh: The factory grease in the XFD131 can dry out or become contaminated over time, increasing friction on the shift fork. Disassemble the gear housing and apply a small amount of high-temp lithium grease specifically to the shift sleeve and the sliding fork. Avoid over-greasing, as excess lubricant can attract debris and actually worsen the "grind."
• Gear Housing Inspection: If the tool has been dropped, the outer plastic housing may be slightly compressed, pinching the shift lever. Inspect the casing around the speed switch for cracks or indentations. If the casing is pinched, you may need to carefully loosen the housing screws slightly to relieve pressure on the selector mechanism.
• Planetary Gear Replacement: If the "popping" persists despite cleaning and lubrication, the teeth on the shift sleeve are likely rounded off (worn). This requires replacing the gear assembly. You will need to source the specific planetary gear set for the XFD131 model; replacing the entire gearbox is usually more cost-effective than searching for individual internal sleeves.
• Spring Detent Replacement: The internal spring that holds the gear in place may have lost its tension or snapped. If the lever moves too freely without any resistance, the detent spring is failed. This requires a full teardown of the transmission assembly to replace the spring.

Heads Up

• Never attempt to shift gears while the motor is spinning. This causes "gear clashing," which rounds off the edges of the selector teeth and leads to permanent popping issues.
• Avoid using the drill in high-dust environments (like sanding or drywalling) without periodically blowing out the gear shift area with compressed air.
• If you feel the gear slip during a high-torque application, stop immediately. Continuing to force the tool while it is popping out of gear can strip the planetary gears entirely, rendering the tool useless.
• Always ensure the battery is fully seated before shifting; low voltage can sometimes cause the trigger to stutter, making it harder to diagnose if the "grind" is mechanical or electrical.