Roomba 650 Wheel Module Disassembly Repair Guide

Difficulty

Moderate

Steps

Time Required

                          25 - 45 minutes

Sections

Side Brush and Bottom Panel
2 steps
Main Wheels
1 step
Roomba 650 wheel module Disassembly
8 steps

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Introduction

What you need

Step 1

              Removing the Side Brush

With the Roomba upside down and turned off, use the Phillip’s 02 screwdriver to remove the one 3.5 mm screw from the center of the side-brush.
Set the screw aside and pull the brush out.

With the Roomba upside down and turned off, use the Phillip’s 02 screwdriver to remove the one 3.5 mm screw from the center of the side-brush.

Set the screw aside and pull the brush out.

1024

Step 2

              Bottom Panel Removal

Unscrew the four screws that hold the bottom panel using the Phillips 02 screwdriver.
The screws will not come out of the bottom panel. They were designed to become loose but not be removed. This prevents you from losing them, and prevents the Roomba from sucking them up if they came out during cleaning.
Once you are sure that all the screws have been loosened as much as possible, then lift the bottom panel up off the Roomba.

Unscrew the four screws that hold the bottom panel using the Phillips 02 screwdriver.

The screws will not come out of the bottom panel. They were designed to become loose but not be removed. This prevents you from losing them, and prevents the Roomba from sucking them up if they came out during cleaning.

Once you are sure that all the screws have been loosened as much as possible, then lift the bottom panel up off the Roomba.

Step 3

              Main Wheels

Unscrew the six 12mm screws holding the side wheels on using a Phillips 00 screwdriver. There should be 3 on each side.
The screws do not come all the way out.
Remove the wheels by pulling them out.

Unscrew the six 12mm screws holding the side wheels on using a Phillips 00 screwdriver. There should be 3 on each side.

The screws do not come all the way out.

Remove the wheels by pulling them out.

Step 4

              Spring

Remove the shock spring to keep the wheel from jumping off when you remove the bolts

Remove the shock spring to keep the wheel from jumping off when you remove the bolts

Step 5

              Suspension

Push the pin that acts as the pivot point for the suspension. I got away with just pushing with a screwdriver
Use pliers to pull from the other end to remove the pin completely
Unscrew all the remaining bolts

Push the pin that acts as the pivot point for the suspension. I got away with just pushing with a screwdriver

Use pliers to pull from the other end to remove the pin completely

Unscrew all the remaining bolts

Step 6

              Take the gear housing apart

Unscrew the housing bolts
Unscrew the two bolts that keep the motor in place
Remove the plastic stopper that keeps the motor wires in place
You should be able to take the motor out now

Unscrew the housing bolts

Unscrew the two bolts that keep the motor in place

Remove the plastic stopper that keeps the motor wires in place

You should be able to take the motor out now

Step 7

              Inside the gear mechanism

With the motor out of the equation, try to move the wheel. If it’s still stuck, than the problem is most likely the fibre buildup inside the wheel housing - as expected
All the gears should slide right off. Except the last one - the one that actually drives the wheel.

With the motor out of the equation, try to move the wheel. If it’s still stuck, than the problem is most likely the fibre buildup inside the wheel housing - as expected

All the gears should slide right off. Except the last one - the one that actually drives the wheel.

Step 8

              Remove the main gear

Remove the main gear using a flathead screwdriver. This is the most difficult step - unfortunately the part was definitely not designed to be serviceable.
This will require a decent amount of force and even though the gears seem to be made out of nylon there’s a chance this one could break

Remove the main gear using a flathead screwdriver. This is the most difficult step - unfortunately the part was definitely not designed to be serviceable.

This will require a decent amount of force and even though the gears seem to be made out of nylon there’s a chance this one could break

Step 9

              Remove wheel

With the main gear out of the way the wheel should slide right off. In my case I had to wiggle it around a bit due to the fibre buildup
It is NOT recommended to rotate the wheel while trying to remove it. The rotation will enlarge the hole of the carrier and make the wheel loose.

With the main gear out of the way the wheel should slide right off. In my case I had to wiggle it around a bit due to the fibre buildup

It is NOT recommended to rotate the wheel while trying to remove it. The rotation will enlarge the hole of the carrier and make the wheel loose.

Step 10

              Clean and reassemble

Remove all the gross hair buildup from the axle. Should come right off.

Remove all the gross hair buildup from the axle. Should come right off.

Step 11

              Done

Much better! As you can see the only thing that keeps the wheel in place is the main gear. there is no problem of the gear slipping because the axle is splined. If you want you can use some threadlock to help securing the gear.

Much better! As you can see the only thing that keeps the wheel in place is the main gear. there is no problem of the gear slipping because the axle is splined. If you want you can use some threadlock to help securing the gear.

To reassemble your device, follow these instructions in reverse order.

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Author

                                      with 4 other contributors

                    Nuno Covas

Member since: 10/01/2017

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Tim Bendt - Oct 2, 2018

I could not get the hinge pin to slide out at all on the 650, so I just disassembled the plastic bits around the wheel enough to get at all the screws on the gear housing.

If you are wondering if this will solve your problem: I confirmed that this was causing a problem because I saw that the metal axle at the center of the wheel was recessed back from being flush the surface of the wheel “hub”. The hair and plastic tag strings had slowly forced the wheel off that shaft so it was rubbing against the side of it’s space and wouldn’t turn properly.

laurent - Aug 11, 2019

Same here. The hair had slowly pushed the pin out and the wheel was rubbing and getting stuck.

Akash Ramsaroop - Dec 14, 2022

Same here also. Easy enough fix!

Cody - Jan 14, 2019

Do you know where to fond replacement gears? Th

swenstyle - Apr 9, 2019

This guide 100% pass for Roomba 681.

Thank you!

p.s.

step 9 was more difficult than 8!

Member-Contributed Guide#

Introduction#

What you need#

Member-Contributed Guide

Introduction

What you need