Milwaukee Sawzall 6520-21 Power Cord Replacement

Written By: Garret Haub
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Milwaukee Sawzall 6520-21 Power Cord Replacement

Difficulty

Moderate

Steps

4

Time Required

15 - 20 minutes

Introduction

Use this guide to replace the Milwaukee Sawzall 6520-21 cord. This provides power to the saw and requires replacement over time.

This guide requires one screwdriver handle and two bits:

  • Size 20 Torx
  • 1.5mm Flathead

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    • 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.

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

    • Lift off the cushion grip.

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    • 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.

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    • 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

Conclusion

To reassemble your device, follow the above steps in reverse order.
Repair didn’t go as planned? Try some basic troubleshooting or ask our Answers community for help.

Author

Garret Haub

Member since: 28/10/24

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