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Chuck Shaft becoming detached from drill motor

I purchased a 1/2'' FireStorm electric drill approximately a year and a half ago from Lowe's. It is a model FS6500HD. I have only used this drill four or five times since I purchased it and it is in almost new condition. Today when I was using it, it began drill okay and then all of a sudden the chuck assembly stopped turning and began coming out of the drill. The entire chuck and shaft assembly just came right out of the drill. The shaft on the chuck did not appear to be twisted or broken into, it just slid right out of the drill, with the drill bit I was using still tight and secure in the chuck jaws. I was shocked as I have never encountered this type of problem. After unplugging the drill I tried to, and was successful in reinserting/
sliding the chuck shaft back into the drill motor housing. I then plugged the drill back in and attempted to continue drilling, but the drill did the same thing again, as the entire chuck and shaft came right out of the drill motor housing. I closely examined the chuck shaft and again it does not appear to be broken or twisted. Also there does not appear to be any signs as to how the shaft was originally attached to the motor housing such as with a snap ring. Up until this point the drill operated perfectly and I have been satisfied with it. Please help.

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  • jcwhis Jun 24, 2009

    Thanks for the reply, I still haven't resolved this problem, I'll check with DeWalt and see what they have to offer. There is no groove on the chuck shaft that slides down into the motor housing so that anything can be clipped on it to secure it to the motor and prevent it from sliding out, and the shaft does not appear to be broken into. This really has me puzzled. I may just have to take it to a service center to get it repaired, but I thought that I might be able to resolve it myself. Thanks again

  • jcwhis Jun 25, 2009

    I live in Vero Beach Florida 32962. I looked at the schematic on, but I still cannot figure out what the problem is. The spindle assembly part #488643 is what I am referring to as the chuck shaft that keeps slipping out of the drill. I can see by the schematic that the spindle slides through the carrier #478748, the output gear #488642 and bearing housing #488624. I also noticed the ring groove near the bottom of the spindle but there is no mention of any snap ring or similiar part that secures the spindle in place in order to prevent it from slipping out of the drill. Thanks.

  • David Ford
    David Ford May 11, 2010

    At least one good thing about taking it to a Dewalt Center they have a max repair rate but I hope it doesn't get that high ( I wouldn't think so) What area are you located in Zip and I might be able to come up with a center close that you can talk to a tech for help

  • David Ford
    David Ford May 11, 2010

    checked out a schematic on this tool and I see what appears to be a ring groove on the spindle but they don't show a retaining ring. This one has got me stumped, but you might want to go to and type in your model number and look at the breakdown with you having the tool it might make some sense. If I had it here I could probably figure it out but their breakdown is not that great.



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  • 33 Answers

Many times there is a allen head screw in the center of the chuck bottom that screws into the shaft of the drill if this screw is missing the chuck will unscrew off the shaft. Many times depending on the size of the drill it is a 10/32 allen screw about 3/4" long that screws into the shaft thru the open end of the chuck.. Sometimes it is a Left handed thread.Check the illustrated parts breakdown for the drill to get the correct part. Hope that helps

Posted on Mar 04, 2017


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Posted on Jan 02, 2017

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SOURCE: dewalt dc920 repair instructions chuck

To remove the chuck on your drill follow the instructions for the type of drill chuck you have:
Instructions for removing a keyed chuck
Most reversing drills have a left hand threaded screw located inside the bottom of the chuck.
1.) If the unit has this screw place the chuck key, with the chuck facing toward you, into one of the holes on the right side of the chuck. Strike the key in a clockwise direction with a wooden mallet or similar object. This will loosen the screw inside the chuck.
2.) Open chuck jaws fully. Insert screwdriver into the bottom of the chuck to engage screw head. Remove screw by turning clockwise this is a left-hand screw.
3.) With the chuck facing toward you place the key into one of the holes on the left side of the chuck. Using a wooden mallet or similar object, strike the key sharply in a counter-clockwise direction. This will loosen the chuck so that it may be unscrewed by hand.
There is no way to stop the motor from turning.
It may require several attempts to loosen the chuck
Instructions for removing a keyless chuck
Most reversing drills have a left hand threaded screw located inside the bottom of the chuck.
1.) If the unit has this screw open chuck jaws fully. Insert screwdriver into the bottom of the chuck to engage screw head. Remove screw by turning clockwise this is a left-hand screw.
2.) Insert the short end of a 1/4" or larger hex Allen wrench into the chuck and tighten. Facing the tool strike the long end of the hex wrench sharply counter clockwise as it is a standard right hand thread. This will loosen the chuck so that it may be unscrewed by hand.
There is no way to stop the motor from turning.
It may require several attempts to loosen the chuck

Posted on Mar 05, 2008

  • 1 Answer

SOURCE: Keyless chuck problem

I had the locking screw come loose in the center and bottom of the chuck it has a left hand thread and is a torx head . It had backed out and prevented the chuck from closing.

Posted on Mar 18, 2008

  • 99 Answers

SOURCE: drill chuck removal

The screw should be left hand thread and the chuck is normal thread. The 'workshop' way to remove the chuck is to remove the screw (done). If the jaws are still working then clamp a sturdy allen key in it and whack it against a workbench to unscrew the chuck. If holding the drill in the normal position you would stand with the workbench to your left and whack it down on that. If the jaws aren't working then you can grip the body in a vice and use large pipe grips or stiltsons on the chuck. Also check to see if the chuck spindle will accept a thin spanner to hold it, as this is a slightly more caring way to brace the spindle. Then you can can hold the spanner in the vice and use the allen key in the chuck and unscrew it that way.

Posted on Oct 25, 2008

  • 99 Answers

SOURCE: removing the dewalt DC925 'rohm' chuck

It should have a retaining screw as far as I know. It may be a torx head in this machine though. Normally left hand thread screw, then normal thread for the actual chuck. It's always worth tightening the chuck a bit before removing the inner screw as it can put pressure on it and make it harder to loosen.

Posted on Nov 29, 2008

  • 2 Answers

SOURCE: bosch 18volt brute force cordless drill how do i remove chuck

Put the screw back in the chuck, tighten it up then back it out 1 turn. Take a punch, put it in the chuck and give it a quick hit with a hammer. That should do the trick.

Posted on Jan 31, 2009

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