Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement

Written By: sebastien_blondeau

Comments: 0

Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement

Difficulty

Difficult

Steps

Time Required

45 minutes

Introduction

This simple guide shows how to remove and replace the blade clamp and the torsion spring on your Milwaukee Sawzall 6520-21 if it does not function properly.

Tools

Step 1

Unplug the Sawzall and Orient the right half-handle to face upwards.
With a T20 Torx screwdriver, remove the following screws:
7-18 x 1.125-inch Slt. Plastite T-20
8-16 x .625-inch Slt. Plastite T-20
The right-half handle does not contain any wires on the underside.
Lift the handle off.

Step 2

Two rubber rings around the divots hold the cushion grip to the handle.
Lift off the cushion grip.

Step 3

Remove the screw above the trigger.
8-16 x .625-inch
The trigger wires threaded through the handle are not fastened. They do not require any tool to pull out.

Step 4

Take a 1.5mm flathead screwdriver and insert it into the pin lock above each of the wires:
Black wire: Insert it on the left side of the pin. Pull the wire while gently rotating it clockwise
Black wire: Insert it on the bottom side of the pin and gently rotate it counterclockwise
White wire: Insert it on the right of the pin and gently rotate it counterclockwise

Step 5

Gently pull the yellow electrical wire.

Step 6

The left half handle and motor housing can separate without difficulty.
The trigger paired with the motor housing wire requires two removals.
Gently remove both white wires.

Step 7

Gently slide the following from the motor housing:
Black chip.
Blue electrical wire.
Two, white electrical wires.

Step 8

Set the shoe release lever in its unlocked position.
Remove the shoe assembly.
There is a pin that holds the shoe release lever
Detach the lever.

Step 9

Push or pull the shoe pin to remove it from the gear case insulator.
Remove the insulator.
This requires a lot of force to remove. It's recommended to have help from another person.

Step 10

Use a T20 Torx screwdriver to remove the following four screws from the gearcase:
K50 x 60 mm Washer Hd. PT Screw
Detach the motor housing from the gearcase.

Step 11

Position the transmission housing upright so the blade clamp assembly faces upwards.

Step 12

Using a flathead screwdriver, insert the head of the driver vertically and twist clockwise to pry the retaining snap ring open and off the blade clamp assembly.
Slide the blade clamp upwards.