Milwaukee Sawzall 6520-21 Motor Replacement

Written By: Garret Haub

Comments: 0

Milwaukee Sawzall 6520-21 Motor Replacement

Difficulty

Difficult

Steps

Time Required

35 - 40 minutes

Introduction

Use this guide to replace the motor of the Milwaukee Sawzall 6520-21. The motor regulates the amount of energy required to operate the saw. This guide's prerequisite is the trigger replacement.

The tools required are the screwdriver handle and the size 20 Torx bit.

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 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.

Conclusion

To reassemble your device, follow the above steps in reverse order.
Take your e-waste to an R2 or e-Stewards certified recycler.
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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