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Posted by on September 1, 2006    |    1 Comment   

So you’re ready to replace the interior components in your drill or you need to replace your chuck. How do you remove the chuck in the first place?

A lot of cordless drills require the removal of the chuck for repairs, especially when repairing the gearbox or torque selector collar. This little guide should help. Please remember that these instructions only work for threaded-on chucks and not taper-fit chucks (almost all cordless drills have threaded chuck spindles). These are helpful hints only and I’m not responsible for any mistakes or mishaps which might happen while removing your drill’s chuck. Please use caution and common sense.

Remove the chuck screw
In many drills there is a small screw deep inside the jaws of the chuck. This screw helps hold the chuck onto the spindle during operation, preventing it from spinning off. Check to see if you have a screw inside your chuck’s jaws. Depending on the brand and model of your drill, you may have to use an allen key, torx driver, or a flat-head screwdriver to remove the screw. The most important thing to remember is this: the chuck screw is reverse-thread. You will have to spin the screw clockwise to remove it. This reverse threading helps to act against the torque of the drill and keep the screw tightly connected.

Prepare to remove the chuck
A lot of people are surprised that the chuck doesn’t just thread off the spindle once the chuck screw is removed. In reality, the chuck is usually torqued very tightly onto the spindle and it cannot be easily removed. Most of the time it’s so tight that the chuck screw can fall out and the drill will operate normally.

You’re going to have to bring out the heavy artillery for this one. You’re going to need a large 90-degree allen key like this one:

Use the largest allen key that your drill’s chuck can accommodate. With most drills this will be a 1/2″ key (pictured above) but some drills can only accommodate a 3/8″ key. Chuck-up the key as pictured below:

Put the short end of the allen wrench into the chuck and let the long end of the wrench hang out. Tighten the chuck down completely.

Bring out the hammer
You’re going to have to hit that allen wrench. Use the flat side of a hammer and hit the end of the wrench (as pictured above). Make sure that the blow will spin the chuck counter-clockwise. Sometimes a chuck is attached very tightly and you may have to hit the wrench hard. Swing through. Sometimes it takes a few swings to loosen the chuck. When you’ve succeeded the chuck will probably spin around a few times and come to a rest on the spindle. You’re done!

Click here to find replacement drill chucks. The finished project should look something like the image above. Good luck!