To split the housing I need to remove the drill chuck and clutch ring. I have removed the chuck fastening screw. 1 What is the trick to detach the chuck, does it slide off or is it threaded to the drive shaft? 2 How does the clutch ring come off?
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Re: Intermitent Electrical fault
As I read from someone on this site. After removing the screw, put a large allen key (short end) into the chuck and tighten. with a hammer tap it in the opposit direction of forward direction. the chuck will then unscrew. then you will be able toget to the screws that hold the chutch ring on.
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Try turning the ring to 2 or 3 and run the drill holding the chuck so the clutch slips then try turning it to drill setting. Also try to do it in different speed settings. If not it sounds like a fault in the gear module. It might just be a metal clip just under the clip in side. Undo the 4 screws holding the gearbox onto the housing and carefully remove it, you might see the fault or loads of dirt that needs cleaning. Go to http://www.2helpu.com/world/map.aspx for a drawing.
Open the chuck wide open. In the center is a retaining screw, they usually have left hand threads. Remove the screw. Take an allen wrench 1/4" to 3/8" in size and fasten the short side tightly in the chuck. The chucks are usually right hand thread, so take a small hammer and strike the allen wrench to turn the chuck to the left to loosen it.
Once you have the chuck off, verify the thread size of the drill motor shaft, then go to McMaster-Carr and choose the one you need.
this tool has a 5 year limited warranty so I would try and have repaired under warranty. I looked at a breakdown and it doesn't specify how the chuck is on but I would to think it is threaded. the clutch is an assembly and there are no replacements parts other than the assembly available. Let me know if you need more assistance.
I have a DC927 and a DC926 that I removed 1/2" Rohm Supra SK key-less chucks on. This process is pretty simple. Put the drill motor in 1st gear. Put the clutch ring in drill mode and not in driver or hammer. Reverse or open the chuck all the way. Hold the chuck firmly in a vise and give the drill a good POP counter clockwise. The last step can also be done with a pipe wrench by placing the drill on a work bench and turning the chuck counter clockwise. Continue to un-thread until the chuck is removed. The replacement chuck must have the same mounting process and mechanism. Put a few drops of locktite on the threads and thread the replacement chuck back on. Tighten the chuck using the vise or pipe wrench. Place the short end of an allen wrench in the chuck and tighten down on it. Placing the drill on a work bench, strike the allen wrench with a mallet to finish tightening and locking down the chuck. Congratulations, you have just changed out your chuck.
First you need to shift the tool to the low position, turn the clutch setting to the drill only position. Open the jaws and remove the chuck retaining screw it is LH threads. After all this find a bent handle allen wrench about the size of the chuck capacity and insert the smaller end in chuck and tighten. Put the chuck on a block or wood or workbench with the wrench at about a 30 degree angle so you can hit the wrench counterclockwise. Strike it with a hammer, it might take a couple times but this usually works. Good Luck
In continuation after removing the chuck screw which is left hand thread shift the drill to LOW and use a bent handle allen wrench approx the size of the chuck lock it in the jaws. Turn clutch setting to the drill only position and using a hammer strike the hex key. The chuck has standard threads. To reassemble just reverse this
Had the same problem on mine. Remove the chuck, then remove the snap ring on the back of the chuck( carefull, the housing will fall out once the ring is removed), on the side of the chuck you'll find a cam and small odd shaped spring held in by two cylender pins, on mine the spring had a gap in it and I just spread the gap to about twice the size in was and put everything back together and it has worked fine ever sence. Hope it works for you.
if your in hurry & away from the service center all you need to do is just loosen the 4 screw that holds the clutch housing & set it # 1 & back to drill mode couple of times. do not remove clutch if your not sure co'z its got tiny needle bearing on front of the transmission.this is just a temporary fix . it may happened again.