Removing chuck on a dewalt hand drill (DWD110)

[pendragon1998]

The chuck on my Dewalt drill was slipping (I presume it was worn out) so I ordered a new chuck and set about removing the old chuck for when the new one arrived. I started by trying to remove the torx screw inside the chuck and I cannot get it out to save my life.

I read that it was a reverse thread, so I was turing clockwise to remove. I sprayed in penetrating oil, even tried heat. I stuck the bottom metal part of the chuck in my vise and used a 18" breaker bar, but the plastic bit turned. So I held the plastic with a crescent wrench and then the top metal bit turned. I tried an electric impact and a hammer-style metal impact, but something is slipping inside. Now the torx bit is stuck in the chuck.

I finally opened the drill and removed the whole chuck assembly to see if I could get at it from behind, but that's where I stopped. I hate to toss a $60 drill and buy a new one when a $15 chuck would fix it, but where can I go from here?

 

[Indexmill]

Try harder to remove that left-hand threaded screw from inside of the chuck.

If that does not work, your only other option is to destroy that stuck chuck and get it off. I wouls set it up in the milling machine or lathe and cut it away. You could mount it in a vise and use an angle grinder to carve it away.

Slow down when you get to the shaft itself and do NOT hit it with the cutter/grinder. Carefully whittle the chuck away from the shaft.

I have done it with big 1/2 Jacobs chucks that just will not come off of a tapered spindle that MUST be saved. Your is a little harder because of that internal screw; just go carefully. It is not that bad one you make your mind up to do it.

Indexmill.

 

[The Cobbler]

as above. cut the end of the chuck off to get easier access to the bolt. and any chuck I have replaced is LH thread.
do you have a hammer impact tool? a few whacks with that might help too.

 

[KnurledNut]

Sometimes you can twist the chuck off and break the screw head in one move with a big pair of pump pliers.
Of course you will then have to extract the screw from the spindle, and purchase a new one.
Kind of a last resort method that works.

 

[zcbauer89]

I did this exact same job today. That torx screw is really in there, held on with a thread locking compound. I think it's a T20 torx? I'd try and get the bit out, and try with a different torx socket, I was able to fit a longer t20 torx socket in there, and loosen it up with a 1/4 long ratchet.

 

[southalabama]

A couple years back I replaced mine. As I recall it took two of us to get it off. A buddy was able to break it lose while I held on to it. More muscle.

 

[wayne55]

If it has threadlocker on it, throw some heat at it.

 

[jeffmoss26]

I had a DeWalt drill that needed a chuck removed, we ended up putting the drill into a Bridgeport and slicing the chuck in half to remove it. I kept one piece and my coworker kept the other

 

[pendragon1998]

Well, I buggered it up with a grinder. $#&*. Who can recommend a good corded drill $50-$100? I need variable speed and reverse. I spend a lot of time with the drill chucked into my vise, using it to spin parts for polishing and sanding.

 

[rvieceli]

Like yellow? They still make that one.

http://www.homedepot.com/p/DEWALT-3-8-in-Pistol-Grip-Drill-Kit-DWD110K/100634626

AND you'll have a spare chuck ;-)

 

[Rdan]

I need to do this to my Dewalt. I have the T-Handled one DEWALT DWD115K 8 Amp 3/8-Inch VSR Mid-Handle Grip Drill Kit with Keyless Chuck. Since I use it for pocket holes mainly, I am replacing the chuck with a Hex bit holder. Since it seems when I run this on my holes the keyless chuck loosens when I put it in reverse. The drill is excellent and has plenty of power. I also own the Milwaukee 3/8" with keyless chuck but is the pistol grip style both have the higher RPM over the 1/2" models that have the lower speed but more torque. Dan

 

[pendragon1998]

Like yellow? They still make that one.

http://www.homedepot.com/p/DEWALT-3-8-in-Pistol-Grip-Drill-Kit-DWD110K/100634626

AND you'll have a spare chuck ;-)

Yeah, I beat the **** out of the old one and it came back for more (even though the chuck quit on me finally, it didn't owe me anything). After looking around at the competition, I'm going to go with this. Thanks.