How to Replace a Porter Cable Power Cord

Disconnect the power cord from the electrical outlet, and place the tool on a work table with sufficient overhead lighting.

Follow the power cord into the tool, and locate the screws that hold the housing surrounding the cord strain relief together. On circular saws and drills, this is in the handle, but on routers, it is on top of the unit.

Remove the screws that hold the housing in place, and lift the housing off the tool, exposing the electrical connections inside.

Loosen the clamp that holds the wire in place. Locate the black and white wires of the power cord and make a note of their connections. If the wires are connected using screw terminals, loosen the screws, and remove the black and white wires. If they are connected with spade connectors, slide the black and white wires off their respective spades.

Pull out the damaged power cord and the strain relief. Slide the black rubber strain relief off the damaged cord.

Slip the ends of the new power cord into the smaller end of the strain relief, and slide it about 6 inches up the cord.

Replace the new power cord and the strain relief into the housing. Position the strain relief in the grooves from which you removed the strain relief in Step 5, then route the black and white wires through the clamp and into their respective positions.

Connect the black and white wires to their spade or screw connections, and tighten the screws (if necessary).

Tighten the clamp screw to hold the new power cord in place. Then replace the removed portion of the housing and secure it with the screws.

Plug in the power cord to the electrical outlet and test the tool.