Milwaukee Sawzall 6520-21 Trigger Replacement

Written By: Garret Haub
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Milwaukee Sawzall 6520-21 Trigger Replacement

Difficulty

Moderate

Steps

6

Time Required

20 minutes

Introduction

Use this guide to replace the trigger for the Milwaukee Sawzall 6520-21. The trigger is used to operate the saw.

This guide has a prerequisite needed for completion. The tools required are a screwdriver handle and two bits:

  • Torx 20
  • 1.5mm Flathead

If the power cord has been removed, no tools are required, and takes 2 minutes to finish.

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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

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    • Gently pull the yellow electrical wire.

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    • 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.

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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