Question about Milwaukee Tool 10 Amp Sawzall Plus with Quick - Lok Cord

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Super Sawzall #6527 Clutch Adjustment

I've had this tool for several years and like it very well. When it was nearly new, the blade shaft quit moving and I took it in for repair under warranty.
The repair tech told me after he had completed the repair that he had set the clutch to slip so that the shaft would not break again when the blade bound up during a cut. He was right, I never even break a blade with this saw. But the clutch disengages so easily that it is difficult and much too time consuming to cut through rough work.
This would seem to me to be a fairly simple adjestment that I can do myself, but I hesitate to open the case of the saw without having an assembly diagram of the machine.
I need to know 3 things. 1) Is this the fairly easy adjustment that I anticipate? 2) Where can I obtain the assembly diagram? &/or 3) Can you tell me how to make the adjustment without the diagram if it is not available.

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  • art_hogan Apr 19, 2009

    Thank you!! I did find the Milwaukee Parts List exploded diagram after I posted the question, but your instructions are great. I'll get the adjustment made yet tonight. Thanks for your timely response.



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The answer to all 3 is yes. The website is and to tighten the clutch you will need a 1/2" socket a vise or similar device to hold the gear along with a piece of rubber or a shop rag that is folded to prevent damage to the gear. What you have to do is remove the shoe, on the side where the release lever is there is a T20 screw that comes out next, remove the lever, pull off gearcase insulator and remove the 4 T20 screws that hold it to the motor housing. Under the insulator you will find 2 plastic O rings don't loose them they go on the shaft that locks the shoe in place. on the front of the gearcase you will find a plastic cap, remove it to find the 1/2" nut put the gear with the protective wrap in a vice and tighten the hex nut, I usually tighten them a little more than snug. When done reassemble in reverse. You can pull up a breakdown at the site listed so you know what I am talking about but it is really quite simple.

Posted on Apr 19, 2009


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