DC759 Chuck came apart

[renrut13]

I have the DC759 cordless, keyless chuck drill. As ithe was trying to change the bit, the black part of the chuck came apart, leaving me with the bit tightened inside the chuck. How can I remove the bit to gain access to the screw to remove the rest of the chuck? I've tried using channel locks to loosen the chuck with no success, please help!

[Tinkerdave]

Hi renrut13,
You will have use a dremel tool with a small cut off wheel and very carefully cut the plastic cover off the chuck exposing the dogs that are arranged in a radially symmetrical pattern.Before going an further view this process for removing the chuck How to Remove a Drill Chuck : eReplacementParts.com.
Then you will have to very carefully rotate the exposed ring that goes around the chuck that tightens the jaws. If you look closley at the ring you will see three or four little levers that need to be pushed down for the ring to rotate and close.Don't break the ring or levers as you will not be able to close the jaws and will then have to cut the chuck off.Hope that helps .Good luck.
Tinker

[renrut13]

Thanks Tinker,
The thing is, there is nothing plastic left on my drill chuck, it all came off. Can I just use a pipe wrench to loosen the bit end of the chuck? It looks like its about an inch-long collar that tightens the dogs that hold the bits.

Renrut13

[Tinkerdave]

Hi renrut13,
Well channel locks would be better.just be careful not to break the ring and be sure to push the locking levers down before rotating it.Good luck.
Tinker

[renrut13]

Thanks again Tinker. But I don't see the locking levers you talk about. I see the grooved side of the dogs and three machined holes about 1/16" deep, but no levers at all.

[Tinkerdave]

Hi renrut13,
Some used levers and some were bands.Go ahead and rotate the collar and see if it moves.If not look for something to release the collar to allow it to turn.Good luck.
Tinker

[renrut13]

Hey Tinker,
No luck with the channel locks. I guess you cutting the chuck of seems like the only solution. Any words of wisdom? Can I just cut the collar that seems to hold the dogs tight then access the screw that holds the base of the chuck?

[Tinkerdave]

Hi renrut13,
Cut the ring off and the pawls should come out of the front of the chuck.Remove the chuck screw ( left hand thread) Put the tool in drill mode and in 1 gear. The chuck is on right hand threads. use a pair of channel locks and see if you can remove the chuck.It seems that some of the chucks were put on with 271 loctite. If this is so you will have to carefully heat the chuck shaft and try again to remove it with a channel locks.Good luck.
Tinker