How to Replace the Chuck and Key on a DeWALT Drill

The chuck adjusts open and closed to securely hold a drill bit. This allows you to use a variety of different sizes. There are three jaws in the chuck that clamp against the drill bit. After years of hard use, these jaws will wear, and your drill bits might begin to slip in the chuck. Sometimes, a jaw inside the chuck can be broken off.

Let's get started.

REMOVING THE CHUCK   1. Remove the retaining screw.

a. Open the chuck as wide as possible.

b. Remove the retaining screw. (The screw is reverse-threaded.)

  2. Remove the chuck.

a. Install a large hex wrench into the chuck.

b. Tighten the chuck around the hex wrench.

c. Strike the exposed end of the hex wrench with a rubber mallet until the chuck breaks free of the spindle. (This may require several attempts.)

d. Unscrew and remove the chuck from the drill.

e. Remove the hex wrench from the chuck.

INSTALLING THE NEW CHUCK

  3. Install the chuck.

a. Thread the new chuck onto the spindle.

b. Install the large hex wrench into the new chuck.

c. Use the key to tighten the chuck around the hex wrench. (Leave the key in the assembly.)

d. Use the hex wrench (for leverage) to hand-tighten the chuck assembly onto the spindle. The chuck key will prevent the assembly from rotating as you tighten it.

e. Remove the hex wrench from the new chuck.

REASSEMBLING THE UNIT

  4. Reinstall the retaining screw.

a. Install the retaining screw.

b. Tighten the retaining screw to secure the new chuck to the spindle. (The screw is reverse-threaded.)