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Milwaukee Sawzall 6520-21 Trigger Replacement

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  1. Milwaukee Sawzall 6520-21 Trigger Replacement, Power Cord: crwdns2935265:01crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 Milwaukee Sawzall 6520-21 Trigger Replacement, Power Cord: crwdns2935265:01crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 Milwaukee Sawzall 6520-21 Trigger 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 Trigger Replacement: crwdns2935265:02crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 Milwaukee Sawzall 6520-21 Trigger 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 Trigger Replacement: crwdns2935265:03crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 Milwaukee Sawzall 6520-21 Trigger 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 Trigger Replacement: crwdns2935265:04crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 Milwaukee Sawzall 6520-21 Trigger Replacement: crwdns2935265:04crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 Milwaukee Sawzall 6520-21 Trigger 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 Trigger Replacement, Trigger: crwdns2935265:05crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 Milwaukee Sawzall 6520-21 Trigger Replacement, Trigger: crwdns2935265:05crwdnd2935265:02crwdnd2935265:02crwdne2935265:0
    • Gently pull the yellow electrical wire.

  6. Milwaukee Sawzall 6520-21 Trigger Replacement: crwdns2935265:06crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 Milwaukee Sawzall 6520-21 Trigger Replacement: crwdns2935265:06crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 Milwaukee Sawzall 6520-21 Trigger 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.

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To reassemble your device, follow the above steps in reverse order.
Repair didn’t go as planned? Try some basic troubleshooting or ask our Answers community for help.

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