April 13, 2022

How to replace a chuck on a drill?

Replacing a chuck on a drill can be a daunting task, unless you follow a few simple steps. First, you need to find the right replacement chuck for the drill you own. This doesn’t take long. Then you need to drill the chuck out of the drill. This part is the trickiest, so take your time. While it may not be the most glamorous task, repairing your drill is a piece of cake—as long as you know what you’re doing. Replacing a chuck on a drill can be an expensive task, so troubleshooting the problem before you shell out big bucks for a new one is a good idea.

How to change drill chuck

Tools and parts

Gather your tools and parts needed to upgrade or replace most drill chucks. However, some have Phillips setscrews, and some newer drills have a Torx screw for the setscrew. Use a screwdriver to remove the set screw or retaining screw.

A hammer is for pushing the jaws into the chuck if the chuck is seized. A pin punch pushes the chuck jaws in. That is if you need to get at the setscrew. Replace a large Allen key with a Hex key that will fit in the chuck.

Choose between a replacement chuck and key. The most common chucks take four different chuck keys. Three chuck sizes ½ ⅜ ¼, two spindles male and female, two spindle sizes ½ and ⅜, and two torque irreversible and reversible.

Removing the chuck

Remove the chuck from the drill. Removing the chuck might not be easy. While the drill is running, chuck and set screw tighten onto the spindle,  it tightens to the spindle. Many nonreversible drills and chucks do not have a set screw. 

Open the chuck jaws until they retract so you can remove the set screw. The set screw is inside the mouth of the chuck. Turn the set screw clockwise to screw the set screw out of the spindle, with the drill pointing at you.

Turn the chuck counterclockwise to screw the chuck off the spindle. The chuck can be so tight to the spindle you will not be able to unscrew the chuck by hand. Instead, use an Allen key or Hex key in the chuck and tighten the jaws on the Allen key.

Tap the Allen key with your hand, so it spins the chuck counterclockwise. Brace the drill on your workbench or vice if you need to hit the Allen key hard. When the chuck is loose the chuck unscrews off the spindle easily. Your hand will not break the chuck lock on the spindle as you hit the Allen key with a hammer.

Open and remove a seized chuck.

Place the key in the chuck, and turn the key counterclockwise. Tap on the ends of the jaws with a hammer. Make sure the jaws are fully retracted into the chuck’s body or flush with the face of the chuck.

To retract the chuck jaws onto the chuck body to remove the setscrew, take a pin punch and tap on the ends of the jaws as you turn the chuck key. You may need to tap on the jaws and then turn the key repeatedly until the jaws retract.

Remove the set screw turning it clockwise.

If you cannot close the jaws onto an Allen key, put the chuck key in the chuck. The key should not be pressing on the ring gear. Tap the key with a hammer, so it spins the chuck counterclockwise. If the chuck key is pressing on the ring gear when you hit the key with a hammer, it can damage the ring gear or the chuck key. Brace the chuck on your workbench or a vice to hit the key hard.

Replace the chuck

The new chuck should go on the spindle, turning it clockwise and the set screw screwing it counterclockwise. That way, you are done upgrading a drill.

How to remove chuck from electric drill

  1. Unplug the drill. Whenever performing repair or maintenance, make sure to unplug the tool first. You cannot allow the drill to start spinning a wrench when you pull the trigger unknowingly.
  2. Remove the retaining screw. Open up the jaws and look for a retaining screw at the bottom of the chuck. If there is a screw, remove it before you unscrew the chuck. Retaining screws have a left-hand thread, so turn clockwise to remove it. Close the jaws until they touch the screwdriver. That helps keep it centred and perpendicular. The screw can be stubborn to come loose if it has a thread locking compound on it or if rusty. An impact driver can do the magic.
  3. Identify the means of grip. Depending on the specific model of your drill and chuck, grip either or both with a regular open-end wrench. Spindles have different shapes. 
  4. Use the twin wrench, single wrench, or no wrench method, depending on the portions you fit a wrench to. The Twin wrench method is more civilised and allows you to apply more controlled force.
  5. If both the spindle and the chuck allow using a wrench, you may need to use a thin wrench as there may not be sufficient space to fit a regular size wrench. Hold the chuck with a right-hand thread. Turn counter-clockwise to remove. With the opposing action of two wrenches, any chuck should come loose.

Black and decker drill chuck replacement

  1. Strike the key in a clockwise direction with a wooden mallet or similar object to loosen the screw inside the chuck.
  2. Open chuck jaws fully. Insert a screwdriver into the bottom of the chuck to engage the screw head. Remove the screw by turning clockwise a left-hand screw.
  3. The chuck has to face toward you, to place the key into any hole on the left side. Use a wooden mallet to strike the key sharply in a counter-clockwise direction. That will loosen the chuck so that it may be unscrewed by hand.

How to remove a seized drill chuck

  1. Open the chuck to the widest position. Use a hammer and punch to score the centre of the retaining screw. That will stabilise the drill bit during the initial stages of drilling.
  2. Drill away the head of the retaining screw. Select a drill bit that is the same diameter as the head of the retaining screw. Align the drill bit with the centre of the retaining screw. Start drilling, ensuring that the drill bit remains centred on the retaining screw. Make regular stops to inspect the retaining screw and remove the metal shavings from the chuck. Do not allow the drill bit to drift into the sides of the chuck. 
  3. Open the chuck to the widest position. Strike the exposed end of the Allen wrench with a hammer. When enough of the screw head has been removed, the chuck breaks free from the spindle. Continue to rotate the chuck assembly using your hand until it disengages the spindle.

Bosch drill chuck replacement

  1. Remove the battery from the drill. If you have the release tab on the rear, press the tab and slide the battery away from the drill.
  2. Rotate the clutch sleeve past the numbers to the symbol that resembles a drill bit. This position locks the clutch. 
  3. Hold the drill in one hand and rotate the chuck sleeve counterclockwise with your free hand to open the chuck jaws. 
  4. Turn the screw clockwise with a Phillips-head screwdriver and remove the screw from the chuck. 
  5. Insert the short end of a 1/2-inch hex key into the chuck, and tighten the jaws.
  6. Tap the long end of the hex wrench with a mallet to rotate the chuck counterclockwise. 
  7. Wipe the spindle head on the drill with a clean rag. 
  8. Thread the new chuck onto the chuck spindle clockwise with your hands. Insert the short end of the hex key into the chuck and tighten the jaws. 
  9. Open the chuck jaws and release the hex key. Install the screw into the inside center bottom of the chuck and tighten it with the Phillips-head screwdriver. Turn it counter-clockwise to install and tighten.

Keyless drill chuck replacement

  1. Remove chuck from the drill
  2. Remove lower housing
  3. Remove upper housing.
  4. Mark the jaws.
  5. Disassemble and clean.
  6. Time the jaws.
  7. Prep the sleeve.
  8. Press the bearings.
  9. Finish reassembly. 

Milwaukee drill chuck replacement

  1. Rotate the chuck counterclockwise.
  2. Remove the 28 mm inner screw holding the chuck onto the drill using a Phillips #3 screwdrivers.
  3. Rotate the screw clockwise to loosen it.
  4. Insert an Allen wrench into the chuck and tighten the chuck onto the wrench.
  5. Rotate the Allen wrench counterclockwise to remove the chuck.
David D. Hughes
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