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This simple guide shows how to remove and replace the blade clamp and the torsion spring on your Milwaukee Sawzall 6520-21 if it does not function properly.
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Unplug the Sawzall and Orient the right half-handle to face upwards.
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With a T20 Torx screwdriver, remove the following screws:
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7-18 x 1.125-inch Slt. Plastite T-20
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8-16 x .625-inch Slt. Plastite T-20
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Lift the handle off.
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Remove the screw above the trigger.
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8-16 x .625-inch
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Take a 1.5mm flathead screwdriver and insert it into the pin lock above each of the wires:
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Black wire: Insert it on the left side of the pin. Pull the wire while gently rotating it clockwise
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Black wire: Insert it on the bottom side of the pin and gently rotate it counterclockwise
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White wire: Insert it on the right of the pin and gently rotate it counterclockwise
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Gently pull the yellow electrical wire.
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The trigger paired with the motor housing wire requires two removals.
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Gently remove both white wires.
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Gently slide the following from the motor housing:
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Black chip.
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Blue electrical wire.
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Two, white electrical wires.
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Set the shoe release lever in its unlocked position.
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Remove the shoe assembly.
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Detach the lever.
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Push or pull the shoe pin to remove it from the gear case insulator.
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Remove the insulator.
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Use a T20 Torx screwdriver to remove the following four screws from the gearcase:
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K50 x 60 mm Washer Hd. PT Screw
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Detach the motor housing from the gearcase.
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Position the transmission housing upright so the blade clamp assembly faces upwards.
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Using a flathead screwdriver, insert the head of the driver vertically and twist clockwise to pry the retaining snap ring open and off the blade clamp assembly.
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Slide the blade clamp upwards.
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To replace the torsion spring, use the flathead to pry the retaining pin beneath its square head.
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Pull the retaining pin out.
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Pull and slide the assembly and torsion spring off of the spindle.
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When replacing the torsion spring, insert the pin into its respective hole within the assembly.
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To reassemble your device, follow these instructions in reverse order.
To reassemble your device, follow these instructions in reverse order.