Question about Milwaukee 6520 21 12 Amp Orbital Sawzall Recip Saw

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How do you change brushes on milwaukee sawsall

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Depends on the model number but, if you can see a black screw on the upper and lower portion of the tool UNPLUG the TOOL and remove the screws and the brushes are underneath. If you don't find the brush caps you need to remove the handle halves and expose the rear of the motor to access the brushes. I would recommend going to and with your model number under service type it in to download a breakdown for this tool.

Posted on Sep 12, 2010

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How to replace milwaukee C18ID brushes

That model may be one of those that really isn't meant to be replaced, you can try to do it. I've been the shop maintenance mechanic and have come across some Milwaukee tools grinders that were made to be throw aways! They made them so you could replace the on/off switches but brushes were the real problems with them. They were so short and tiny that they would wear out within a month of constant use. If the brushes didn't go the bearings would melt and the entire case would need to be replaced. The brush assemblies may be available if you order them from Milwaukee directly.

They are not like they old style that would be a piece of brush with a copper braided lead protruding out. Those would just drop into the slots and the spring holds pressure on them. You can find some brushes and shape them yourself as I have done with these newer tools. You'll find the springs are now part of the holder assembly and is a curled piece of spring steel that holds the pressure. So be careful if you try to reuse the assembly with another generic brush set. They will have a special shape also to deter you from using a longer lasting brush by having an offset in the design or a groove which can be flattened. I found the shapes to be like 2 squares that are offset but a rectangular shaped brush will work after its reshaped by a sander or grinder. The Milwaukee brush was 1/4" long new, replaced with 5/8" once the holder was modified, then the bearings just melted, cases melted and the motors rubbed on the windings. But I never had to replace the brushes again. Average life was between 2 weeks to 4 months (new), Hitachi similar grinders lasted 5 or more years with 1 or 2 brush replacements.

Either way you're going to take the tool apart yourself to replace them, just depends on the availability of replacements assemblies. Also the cost, you may as well order 4 sets right away if you are going to use Milwaukee's new garbage sets. 20 years ago I used a similar grinder for 5 years of constant every day use, replaced the cord a few times, never had any other problems.

Now I wouldn't even bother to take them apart, just about every other brand made is equal to or better than Milwaukee and cost 1/2 as much plus they use interchangeable parts. Now you're paying for Milwaukee's redesigning and engineering teams quest to constantly change parts, making sure that you cannot service them using any old parts. Right down to the cords, they spend all their money on developing new ways to do the same thing but making sure it is not compatible with last years models parts. Once your tool is made outside the USA there's no reason to buy any 1 brand, they will all be the same in the end and just dyed a different color and have labels stuck on the cases.

Sep 23, 2014 | Drills

2 Answers

Why wont my Milwaukee impact driver work when I pull the trigger ?

If the accu says Hi I am Full on the test button , i say short REPLACE ancre(armature AND carbon brushes together. remember if you have short brushes and you are working professional every day with this tool your brushes are AGAIN be shorted in a few weeks . 4 brushes in a brushholder and be carefull with soldering on the realy expensive switch if to long heat on the contacts it will also defect . MArketing technical position numbers to buy on differend models can be possible ask your dealer for a cheaper deal because what realy needed is the armature and the brushes not that complete unit , its a milwaukee marketing option because of the price Unfortunately
23 66 1239 Switch Handle Kit

but this is a real solution

Panasonic has with this kind of Johnson brushmotor exactly the same problems with Ey 7441 model after a few years of using by heat dissipation internal thermical or not thermical shorting of wires of the armature it is highly audible by a piercing sound

14 46 2018 Carbon Brush Kit

and together with this 16 01 3010 Service Armature Assembly

look this JOHNSON kind of difference in the
changed way of wrapping armatures and the old way was good but the new way delivers more power but also heat and that will make the trouble look here the differences of the old and the new


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1 Answer

I cannot find a replacement part for my Makita mod. JR3000 recipricating saw. I need a handle.

Call Makita at 1-800-462-5482 they will sell direct. Sawzall is a Milwaukee trade name so when you call say reciprocating saw. You'll also need the serial number or date code because Makita has several revisions to that tool.

Dec 27, 2012 | Saws

1 Answer

I need to repair a switch on a milwaukee super sawsall

before change the switch,check 120 volt wire and brush
also check for loose terminal on brush holder,sometime look ok but you can see littlebit of melted plastic at the crossing of plastic and terminal
with more then 12 years to repair tools,when i open the handle,i weld the terminal to holder to eliminate futur problem,it take 2 minutes

Nov 17, 2012 | Milwaukee Tool Saws

1 Answer

Cutting an opening in a steel door for a doggie door. Bought a Sawsall just for this. Any tips?

be sure to use eye protection and gloves to protect you from sharp edges.
first mark your lines on the door using a square, then drill holes large enough for the sawzall blade to fit through in all 4 corners. next use the sawzall to cut your straight lines which were alraedy marked and you now the opening you need. if necessary use a file or dremel tool to clean up and debur edges. hope this was helpful, if so please rate.

Feb 17, 2011 | Milwaukee Tool Milwaukee Super Sawzall...

1 Answer

Milwaukee 5616-29 when turning on, spins up then shuts off.

it sounds like the brushes on your router need to be replaced. It is best to use the milwaukee replacement brushes available from any milwaukee service center.

Oct 02, 2009 | Milwaukee Tool Milwaukee 5616 24 2 ¼ Max...

1 Answer

Procedure to chamnge brushes on 1/2"Milwaukee Hammerdrill 5376-1

Yes look at the brush holder you will see a tiny hole in it push the brush just past the hole insert a paper clip or wire that will allow you to get it out after you get the armature in if you need more help let me know.

Jul 11, 2009 | Milwaukee 0799-20 V28 7/16" Quick Change...

1 Answer

How to replace the brushes on the milwaukee cordless drill 1/2'' # 0627?

Depending on age of tool older models did not have replaceable brushes. Change motor.
Newer models are replaceable , go to a service center and get a brush kit for this model. Or online.
Open tool with # 8 torx. Do not separate motor and gear case ,chuck remove as one unit. Brushes are solder in .De solder used brushes . Replace one side at a time. These kits come with new coil tension springs .

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1 Answer

Plugged electric sawzhall in, no power. checked cable -- ok, checked both brushes, still have about 3/8in in each of them. What should I do next? Just replaced the blade, but I do not think that has...

I would say its either in your cord(an open wire from wear) or the switch on the sawsall.
Try plugging it in and hold in the switch (dont have a blade in) move the cord around in different places to try to get it to work if thats not it and your brushes are ok its probably the switch. I ve replace bad switches in sawsalls before from wear. You can either go to your local electrical supply store that sells milwaukee and order one or I ve purchase them at Grainger parts too.

Jun 29, 2009 | Milwaukee Tool Milwaukee 10 Amp...

1 Answer

Milwaukee Sawsal Broken blade

Spay inside where blade fits in with PB BLASTER & let set a while. Maybe you will get lucky & the blade will fall out as it should. If not then it will have to be dissembled in this area. There are 2 BB's inside that fit into the small hole on the blade. They are forced in by a spring, be careful not to lose these. Also check the accuatator when you pull the finger release, make sure it is going all the way or it is not broken, Good luck.

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