Dewalt DW953 Type 5 chuck screw

[dray]

I've watched the video for cordless chuck removal. Unfortunately, there are two conditions (affecting my drill) which aren't covered. First the torx screw holding the chuck on will not turn. I've broken two tips trying. Second, presuming I get the screw out, the allen wrench idea won't work because the chuck is jammed (the reason I need to replace it in the first place). I suppose I could replace the shaft itself but I'm not sure it's necessary. Any ideas out there?

[TERRY P]

One thing that sometimes works is to try to "tighted " the chuck onto the shaft a little. Sometimes the chuck backs off a bit and puts alot of pressure onto to screw, by trying to tighten the chuck down a bit first it will release some of the pressure on the screw. Since yuor chuck is jammed try this.... Put the drill into "low" gear( #1) then make sure the clutch setting is all the way into drill mode. Clamp the chuck assembly itself into a large vise with the drill body sticking straight up and try turning clockwise very sharply and hard (trying to tighten the chuck down ). Remove the drill and try again to remove the screw ( which on the dewalt is a torx size t-20 and left hand thred (clockwise to remove). Once the screw is out try the same method to remove the chuck. Clamp the chuck tightly into a vise and give it a hard sharp snapcounter clockwise to remove. ..... Good luck and let us know how you made out

[qdea]

I'd like to take this opportunity to share one of my experience and method of taking it off ( which actually works) looking at the photo of the cross sectional view of the chuck as seen in an earlier thread. I first measure 1" from the back of the chuck and I make a mark,then I take an old/new hacksaw blade and I make a mark on the chuck outside.and thats where I take an angle grinder and I cut the front of the chuck off so that I can access the back end of it,and then I hit the rest off using a small cold chisel in the same direction as if I was unscrewing it. The whole process usually takes me about 15-20 mins to complete,but it worked

[dray]

Well, I had to wait a while to get a couple of 2" #20 Torx tips to give it one last try and both "bit" the dust in vain. I then started cutting away the body of the chuck ( as was suggested by gdea) exposing the three jaws. By cutting all three jaws through to the round( I don't know what to call it) I found that whatever had jammed the chuck had been released!!! Probably one of the jaws had become misaligned and prevented the chuck from screwing.( A terrible thing indeed!!) Anyway, I wanted to thank those of you who responded and relate what turned out to be a fairly easy fix to my problem- at least when I finally tried it.. (Or was I just lucky-I don't know!)

[gupp2]

First off an allen wrench will not remove the torx head screw, and you may even strip the head of the screw trying to remove it.

Dewalt DW953 drill chuck screws use the T20 Torx head screw, and the body uses the T15 Torx head screws. I use the Craftsman Torx head screw driver set, which has all the common sizes.

The T20 Torx head screw is left hand threaded, which means you will have to unscrew it by turning the screw to the right (clockwise). Most traditional screws are right hand threaded and are tightened turning them to the right (clockwise).

Try the torx tip screw driver before attempting any other method.

If for some reason the head is stripped you can drill the head of the screw off only. Requires several sharp bits lubed with small amount of oil and slow drill speed, starting with an 1/8" bit or smaller for your pilot hole, then use a 3/16" drill bit to remove the head only. You can now use the allen wrench method to remove the chuck ( Removing a Cordless Drill Chuck ).