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Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement

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  1. Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement, Power Cord: crwdns2935265:01crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement, Power Cord: crwdns2935265:01crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement, Power Cord: crwdns2935265:01crwdnd2935265:03crwdnd2935265:03crwdne2935265:0
    • Unplug the Sawzall and Orient the right half-handle to face upwards.

    • With a T20 Torx screwdriver, remove the following screws:

    • 7-18 x 1.125-inch Slt. Plastite T-20

    • 8-16 x .625-inch Slt. Plastite T-20

    • The right-half handle does not contain any wires on the underside.

    • Lift the handle off.

  2. Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement: crwdns2935265:02crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement: crwdns2935265:02crwdnd2935265:02crwdnd2935265:02crwdne2935265:0
    • Two rubber rings around the divots hold the cushion grip to the handle.

    • Lift off the cushion grip.

  3. Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement: crwdns2935265:03crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement: crwdns2935265:03crwdnd2935265:02crwdnd2935265:02crwdne2935265:0
    • Remove the screw above the trigger.

    • 8-16 x .625-inch

    • The trigger wires threaded through the handle are not fastened. They do not require any tool to pull out.

  4. Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement: crwdns2935265:04crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement: crwdns2935265:04crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement: crwdns2935265:04crwdnd2935265:03crwdnd2935265:03crwdne2935265:0
    • Take a 1.5mm flathead screwdriver and insert it into the pin lock above each of the wires:

    • Black wire: Insert it on the left side of the pin. Pull the wire while gently rotating it clockwise

    • Black wire: Insert it on the bottom side of the pin and gently rotate it counterclockwise

    • White wire: Insert it on the right of the pin and gently rotate it counterclockwise

  5. Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement, Trigger: crwdns2935265:05crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement, Trigger: crwdns2935265:05crwdnd2935265:02crwdnd2935265:02crwdne2935265:0
    • Gently pull the yellow electrical wire.

  6. Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement: crwdns2935265:06crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement: crwdns2935265:06crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement: crwdns2935265:06crwdnd2935265:03crwdnd2935265:03crwdne2935265:0
    • The left half handle and motor housing can separate without difficulty.

    • The trigger paired with the motor housing wire requires two removals.

    • Gently remove both white wires.

  7. Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement, Motor: crwdns2935265:07crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement, Motor: crwdns2935265:07crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement, Motor: crwdns2935265:07crwdnd2935265:03crwdnd2935265:03crwdne2935265:0
    • Gently slide the following from the motor housing:

    • Black chip.

    • Blue electrical wire.

    • Two, white electrical wires.

  8. Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement: crwdns2935265:08crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement: crwdns2935265:08crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement: crwdns2935265:08crwdnd2935265:03crwdnd2935265:03crwdne2935265:0
    • Set the shoe release lever in its unlocked position.

    • Remove the shoe assembly.

    • There is a pin that holds the shoe release lever

    • Detach the lever.

  9. Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement: crwdns2935265:09crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement: crwdns2935265:09crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement: crwdns2935265:09crwdnd2935265:03crwdnd2935265:03crwdne2935265:0
    • Push or pull the shoe pin to remove it from the gear case insulator.

    • Remove the insulator.

    • This requires a lot of force to remove. It's recommended to have help from another person.

  10. Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement: crwdns2935265:010crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement: crwdns2935265:010crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement: crwdns2935265:010crwdnd2935265:03crwdnd2935265:03crwdne2935265:0
    • Use a T20 Torx screwdriver to remove the following four screws from the gearcase:

    • K50 x 60 mm Washer Hd. PT Screw

    • Detach the motor housing from the gearcase.

  11. Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement, Blade Clamp and Torsion Spring: crwdns2935265:011crwdnd2935265:01crwdnd2935265:01crwdne2935265:0
    • Position the transmission housing upright so the blade clamp assembly faces upwards.

  12. Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement: crwdns2935265:012crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement: crwdns2935265:012crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement: crwdns2935265:012crwdnd2935265:03crwdnd2935265:03crwdne2935265:0
    • 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.

    • Slide the blade clamp upwards.

  13. Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement: crwdns2935265:013crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement: crwdns2935265:013crwdnd2935265:02crwdnd2935265:02crwdne2935265:0
    • To replace the torsion spring, use the flathead to pry the retaining pin beneath its square head.

    • Pull the retaining pin out.

  14. Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement: crwdns2935265:014crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement: crwdns2935265:014crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement: crwdns2935265:014crwdnd2935265:03crwdnd2935265:03crwdne2935265:0
    • Pull and slide the assembly and torsion spring off of the spindle.

  15. Milwaukee Sawzall 6520-21 Blade Clamp/Torsion Spring Replacement: crwdns2935265:015crwdnd2935265:01crwdnd2935265:01crwdne2935265:0
    • 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.

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