![]() Reinstall the gear case and motor back in the housing, aligning it up properly to lock into the housing. Remove the motor from the transmission and insert the motor into the new transmission. Remove the cover and transmission clutch assembly and pull the gear selector switch out. Remove all of the screws on the cover that secure it to the housing as well as the screws securing the transmission clutch assembly. Before doing this, make sure the transmission is set to the lowest setting. Hit the allen wrench with a hammer to loosen. Next, insert a large allen wrench inside the chuck and tighten the chuck down on it. Insert a screwdriver into the drill chuck and remove the screw by turning it clockwise, remembering it is reversed thread. To replace the gear case, first remove the end cap on the drill and then release the brush springs. If the motor spins, but the drill chuck does not or only works in certain gears or clicks like it is jumping gears/gear teeth, then you will need to replace the gear case. If the gears are worn down, this would cause this symptom. ![]() Insert the screwdriver inside the drill chuck to tighten the chuck screw, remembering that the screw is reversed thread. Use the key to tighten the drill chuck on the drill, then loosen the drill chuck and remove the allen key. Install the new drill chuck by threading it on the spindle and then insert the allen key and tighten the chuck on the key. Once loosened, continue to remove from the spindle. A second method is to hit the allen key quickly with a hammer to loosen. Now, insert a pipe over the allen key for leverage and turn counter clockwise to loosen the chuck. With the screw removed, insert a big allen key in the chuck and tighten firmly. Once you have broken the tightness of the screw, loosen the chuck and continue to remove the screw. ![]() Snug the chuck against the screwdriver and loosen by turning it clockwise (this is reversed thread). If you determine that the drill chuck needs to be replaced to solve this problem, begin by inserting the proper screwdriver into the chuck to remove the screw at the bottom. Remember, this screw is reversed thread so turn it counter clockwise to tighten. To solve this problem, insert the proper screwdriver in the drill chuck and tighten. If it is loose, it can prevent movement of the teeth. If the chuck is stuck open, check that the screw inside the drill chuck is fasten tight. However, if the problem continues, replace the drill chuck. If they are not even at the tip, you can gently tap them in place with a hammer to realign. With the drill bit removed, close the chuck and inspect the jaws for alignment. If it is seized closed, you can release the jaws with channel lock pliers. If the drill chuck is seized open, or closed, it will need to be repaired. Get this: The total price for the new drill and the shipping was less than a third of what the drill cost new! I received the drill a few days later and was back in business again.The drill chuck holds the drill bit in place with jaws that firmly clamp down on it. He said that my drill was beyond repair, but they would send me a newly remanufactured drill that was the exact same model as the one I sent in. Within a few days, I received a call from the service tech. Take my toasted drill…I sent it in via a flat rate shipping box from the post office to the indicated address. The repair cost is NEVER more than a set amount for that tool. What that means is if you send in your drill because it has a broken switch, they only fix the switch and charge you for that plus the shipping back to you. They promise the price of a repair will not exceed the published replacement price for that tool. This takes the guesswork out of the repair process. The Factory Owned DeWalt Service Centers use the Guaranteed Repair Cost (or GRC) Program. I gave them a call, and they explained to me the whole scenario. Conveniently, the factory sits just an hour away. From there, I followed a link to find my nearest factory service center. (Actually, I would love to have a new DeWalt lithium-ion XRP hammer drill which recently came to market.) Really, Don’t Throw Away That Broken DeWalt Tool Let’s face it, in these tight times, the last thing I wanted to do was fork out three hundred bucks for a new drill. One day, a few months later, a friend told me about the DeWalt Repair Service program. I put it under my bench and forgot about it for a while. I didn’t have the heart to get rid of my old friend just yet.
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