Base

- Remove grill plates and all other loose metal parts in the grilling area. Remove drip pan. Remove Propane tank (turn of tank first)
- remove doors if they are not screwed in on the bottom
- Carefully lay grill down and elavate the base (i used bricks and 2x4s ) to alow the base to hang without touching the ground. I eventually ... Read more just flipped my entire grill upside down which made the repair much easier
- remove little screw holding each door on carefully and remove each door carefully as they will just fall out
- remove other 6 screws holding base on
- Remove two casters from old base (if they are still on! Mine were completely snapped off, hence the new base)
- Remove wheels/axle from old base (the hard part) - You can use two vice grips to accomplish this. Clamp one vice grip tightly on the axle itsself to keep it from spinning. Clamp the other vice grip around the axle hat nut. spin the axle hat nut counterclockwise until it comes off. remove wheels and axles from old base.
- Insert Axles and wheels into new base (on the same side which you took them off on the old base!). Use a rubber mallet or hammer to push the axle hat nut back on.
- insert casters into new base (also a bit hard to do). I used a few pieces of scrap wood to prop under the base to keep it level while i pushed in the casters. I used another small pice of wood and a rubber mallet to bang the casters in completely. The casters have a flat spot on the bottom in the middle of the wheels which im pretty sure is for the exact reason of hammering them in like i did
- with your grill side ways and propped up or completely upside down, set new base on the bottom.
- insert each door back in carefully and secure little door screw on bottom (if you had them on in the first place, otherwise add the doors last)
- screw in the 6 screws to secure the base. don't tighten them all the way until all of them are in place a little bit, then fully tighten.
- Get a buddy and carefully flip the grill over without putting any pressure on the base or the wheels or casters
- put metal grill parts back in
- put propane tank back in