Milwaukee Rotary Tool Repair - How to Fix it!

I bought a broken Milwaukee Rotary tool from eBay. It was advertised as spares or repair.
Let's fix it!
I've fixed quite a few Milwaukee Items, please check out my other videos!
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Parts used in this repair:
1 x IRF1404 T0220 MOSFET
1 x 12CWQ04FNPBF DIODE ARRAY SCHOTTKY 40V 6A DPAK TO-252-3
#electronics #electronicsrepair #milwaukeetools
how to fix a Milwaukee rotary tool
Milwaukee rotary tool repair

[@biohaz360]

Great fix and hopefully other people will see this video. We talked in the comments on another video about these and I'm thankful you figured out what breaks on them. As to why I'm confident it's stalling the motor while in use, say your cutting disc binds up and stalls it, well it will start up again but you will have to turn up the speed controller above 2 to make it spin up.

[@biohaz360]

Also Dremel has a brushless version out, but the battery life is apparently 15 minutes and you can't buy bigger capacity batteries for them, at least not in States. It doesn't help that Bosch, who owns Dremel, isn't popular here, almost everybody uses either Milwaukee/Ryobi, Dewalt/Lowes version of Craftsman, or Makita.

[@BuyitFixit]

I knew someone had asked about them but I couldn't find the comment to let you know that I'd managed to get one. Thanks for the reply and glad you enjoyed it!

[@SuperMurrayb]

Thank you for posting this informative video. It is common for the MOSFET to fail in these tools after a few hours of moderate use. The heat sink is not very large nor is it finned and there is no other metal to spread the heat. It would be interesting to measure how hot the MOSFET gets during use because excessive heat could cause the switch to fail prematurely. These tools have had the same problem for years but still get mostly four and five star ratings online which is just weird.

[@BuyitFixit]

Thank you for your kind comment. I'm not too sure how often these mosfets fail because I've had some quite new tools with failed mosfets but also own some tools that are a couple of years old which are still running fine. I wonder if it's a tool jamming or something and the user keep pressing the trigger, putting too much strain on them?

[@SuperMurrayb]

@@BuyitFixit There is no trigger it is just a switch. I was just cutting some aluminum downspouts and it suddenly quit. When I cycled it off and on again the lights flashed but the motor would not run. If I turned it on and then removed and replaced the battery it went fully on no matter how the dial was set. After searching online for "Milwaukee rotary tool flashing lights" I discovered it was a common problem. Since I need a reliable tool I scrapped the 2460 even though it was still under warranty and bought a Dremel 8220 to replace it. Your video clearly shows the tiny sheet metal heat sink that could have been the root cause of the failure. What were they thinking? Thanks for posting the video.

[@BuyitFixit]

Ah sorry, KZbin studio on my phone just shows a message and not what video it relates to. I thought it was related the SDS drill or Circular Saw. Perhaps the mosfet isn't up to the job or like you said the heatsink isn't big enough to dissipate the heat.

[@SuperMurrayb]

@@BuyitFixit No need to apologize. Your videos are priceless because they give an impartial and detailed view of the inside of tools. The 2460 rotary tool is one of the worst ever made. The tools have been failing prematurely for over a decade now. Most other M12 tools do not have problems like that. What does not make sense is how the 2460 can be as highly rated as something like the 2526 oscillating tool which is probably the best in its class. Both tools have more than 80 percent four and five star reviews but the difference is like night and day. How can the worst tool in its class possibly have the same high rating as the best in class tool? Something seems very wrong with those ratings. Anyway, good luck with your videos and thank you for posting them.

[@wuvgl]

@@SuperMurrayb i agree every word u wrote.thank u for writing all them down saving me all that time.i also have the oscillating one.also started shopping for dremel but hard to decide cause i'v alot of m12 bats.

[@Sortskjegg]

Mymatevince did a shoutout for your channel in the latest patreon-video, so I thought I'd check out your channel, and I'm liking what I'm seeing. Nice fix!

[@BuyitFixit]

Thank you Roger! Much appreciated!

[@mikethedigitaldoctorjarvis]

People give me stuff like this,most of them say if you fix it you can keep it ! ended up with a few good tools that way.

[@BuyitFixit]

Great stuff Mike! But does that mean if you don't fix it they want it back? lol

[@mikethedigitaldoctorjarvis]

@@BuyitFixit Nah ! 🤣

[@wuvgl]

the speed controlon mine stopped working& now stuck on hi speed.is the diode,mosfet, still ok do u think?

[@BuyitFixit]

The mosfet controls the speed. If it shorts it will sent full power and you'll have no speed control.

[@wuvgl]

@@BuyitFixit is IRF1404z TO220 IC the same and will work?

[@fixinrustystuff]

Ever repaired a Dremel? Would be good to see a fix! Great vids btw!

[@BuyitFixit]

I don't recall looking at a dremel. I wouldn't expect much inside apart from a motor and speed control.

[@dahaze140]

👌>>>Awesome video, I ordered one from craigslist damaged, waiting for it to arrive! Your vids are the best!

[@BuyitFixit]

Thanks Rob! Glad you enjoyed it!

[@stefanofinotto686]

Good morning from Italy. if you allow me, you have a great mind, capable hands. congratulations for the videos. Ciao

[@BuyitFixit]

Thank you my friend 👍🙂

[@MrEwool]

Great work, that was a whole lot of components in a small area. The typical fault finding on power tool is mosfets and diodes, learned that much by now. But as always great video and looking forward to the next one

[@BuyitFixit]

Thanks again Morten!

[@cccEngineer]

This has soured my experience with Milwaukee. I just bought one and used it twice and it's giving me the issue shown at the beginning. I'll probably be staying away from Milwaukee parts from now on

[@BuyitFixit]

Shame, some tools I find really good, others not so good. I'd keep away from the circular saws, and this tool. The drills / grinders etc are really good.

[@michaeltardi3179]

Tomorrow’s project ! Thanks!

[@BuyitFixit]

Good Luck 👍

[@michaeltardi3179]

@@BuyitFixit didn’t work out so well . But I tried . That’s what counts! Thanks

[@599miata]

That will be a great tool for you. Nice repair video, mate.👍👍

[@BuyitFixit]

Yes, thanks I've used it a few times 🙂

[@yosh1don]

Fantastic fix!

[@BuyitFixit]

Thanks!

[@wewillbfree63]

Thanks for showing me that this fix is beyond my capabilities

[@BuyitFixit]

If you have a steady hand and the equipment.The rest is just practice...

[@yosh1don]

​@BuyitFixit did you test the mosfet with the multimeter in diode mode? If so, what reading would you have expected if ut was good?

[@yosh1don]

​@@BuyitFixitfantastic fix btw!

[@BuyitFixit]

If it's bad you usually get a dead short across two or more pins.

[@V8SKULLS]

I have the exact same tool & problem. I would like to know if it's possible to share the link of parts or where to buy them. I want to fix mine as well. Wish I could send you mine to fix. And fixed right. Thank you for you time and wonderful videos

[@BuyitFixit]

Hi, Thanks for that V8SKULLS👍 I've updated the video description with the parts that I used. I just ordered the parts from two different sellers on eBay.

[@arymonem]

Excellent video! Thank you

[@BuyitFixit]

Thanks 🙂👍

[@rbedwar12]

It's just awesome watching the videos...great job...

[@BuyitFixit]

Thank you so much 😀

[@wherami]

Wonderful job as usual!

[@BuyitFixit]

Thank you so much 😊

[@thetraindriver01]

Nice job 👏

[@BuyitFixit]

Thanks 👍

[@Dave-yo9tt]

Great fix... The red wire appears to have a pinch mark on it. Maybe ten pounds of stuff in a 5 pound bag?

[@BuyitFixit]

Thanks Dave 👍

[@davidantrin7935]

The shaft bearing is loose on mine. I tried putting ashim in and it helped, butvdidntvwkinivate it. I could uee a better shim I guess. Or I was thinking maybe take some JB weld putty and roll it into a little "string" and then put it between some kapton tape (I don't want it to melt of the bearing gets hot) and then put that in there so it squishes and takes up all the gap, the sets. But I'm going to send it in for warranty and see if they do anything.

[@dianeramakers3368]

Nice work.

[@BuyitFixit]

Thanks Diane, I had a bit trouble finding the chip, but eventually found one on Aliexpress, was worried it might be a fake as I've had a couple of fake chips before but it seems it was good 👍

[@tomharris1457]

Another Milwaukee win!

[@BuyitFixit]

Yes, I've fixed a few Milwaukee tools. There are a few tools which a lot seem to have the same problem. This is one of those.

[@ianhelsbyservices]

I'm surprised they used a brushed motor considering the quality of their brushless tools. The bearing sounds a little rough for something hardly used. Hopefully it'll do what you need. I've used cheaper corded ones in the past and burnt them out in 20mins use.

[@BuyitFixit]

Thanks Ian. I don't really have a use for one, but I know there was a few people having issues with them so I thought I'd pick one up and hopefully the video helps someone repair it if it's out of warranty! Also it may come in handy at some point...

[@thomaspolley4977]

I was thinking it sounds like it has a vibration. Like the shaft is bent. Mine doesn't sound like that. Maybe it was dropped?

[@BuyitFixit]

@thomaspolley4977 Could well be been dropped. Thanks for the suggestion 👍

[@vermhot]

Kinda sounds like that front bearing is bad . But good fix !

[@BuyitFixit]

Thanks 👍I think the bearing is ok. It felt smooth, I think it could be the shaft slightly bent.

[@brianwengel6894]

How if the "extra" battery pin connected? Let's say I wanna connect this tool to my bench power-supply - I'm sure the tool will not run if I just connect + and - to the main battery-connectors

[@BuyitFixit]

It's just a thermistor to detect baytery over temperature. A 10k resistor to the pin and then to gnd or +v (sorry cant remember which) should do the job 👍

[@barryweissburg6384]

Made in China! Just purchased mine today!

[@BuyitFixit]

Hopefully it doesn't end up needing repaired like this one😂😂

[@rbedwar12]

How do u get them type of tools.. I can't find any...

[@rbedwar12]

Looked on everything...

[@lostsoul3535]

I stalled mine at the lower settings and poof. Had the same problem as the one you fixed. Poor design without any protection.

[@BuyitFixit]

Yes, it seems to be a common problem on these tools 🙁

[@pasqualeparente9776]

My goes on as soon as I install the battery. I can’t turn it off or use the variable speed. I tried to take it apart and tested the mosfet and believe is is shorted. Seeing no value between the legs of the mosfet. But I have very little experience with this type of diagnostic work.

[@BuyitFixit]

Usually a mosfet blows short circuit. I'm not sure how you were measuring. If your meter has continuity or diode mode try that to see if it is shorted.

[@wuvgl]

does shortage mean there's no continuity?

[@BuyitFixit]

@@wuvgl No, if a component blows short circuit you will get almost the same reading as shorting both of the meter leads together. Most mosfets fail this way. They can explode internally after they fail (depending on how much current they are passing) which sometimes results in them being open circuit (same reading as the leads being not connected to each other).

[@RScottMelton]

Does anyone know how to replace a bad bearing on the shaft?

[@BuyitFixit]

Sorry I've not changed the bearing on one. I'd imagine you have to remove the chuck and it would probably tap off?

[@user-te1le7ck6b]

Great fix , that switch looks a poor design mind , Milwaukee don’t seem to use the best components given the faults you find , win for you though

[@BuyitFixit]

Thanks G! Much appreciated!

[@ianhelsbyservices]

Milwaukee seem to be in high demand. Even spares or repairs, they don't come easy, plenty of bids on eBay

[@BuyitFixit]

Yep! A bit like the sander I bid on that had the broken motor. I was nearly out of pocket on that one!

[@bikerdave1274]

yerp imma stick wiv my (tried true n tested) method of enduring excruciating tooth pain until the root feckin dies n it later plops out

[@wuvgl]

can i use IRF1404Z TO220 IC or IRF1404Z TO220 IR ?

[@BuyitFixit]

I'd think so as long as the current rating and pinout are the same.

[@wuvgl]

@@BuyitFixit thanks much

[@janeandtomlowell1222]

How do you replace the bearing

[@BuyitFixit]

You'd probably need to pull it off with a bearing puller perhaps? Or get creative and make something. I've not changed one so that's my best guess.

[@WombleUK]

The quality of the electronics in Milwaukee tools is absolutely appalling. I currently have a knackered M18 CCS66 & M18 Surge Hydraulic Impact Driver where the replacement electronic spares alone cost almost the same as replacing the tools new. I not had a single electronic component fail in my Dewalt, Fein, Festool or Makita tools but I have had M12 battery fail, M18 DAB Radio fail, M18 combi drill trigger fail & M18 Impact speed selector fail all of which were replaced/repaired under warranty & now the surge & circular saw not worth fixing 😡🤬😡🤬

[@BuyitFixit]

I know exactly what you are saying. The circular saws don't seem very robust as I've often seen them listed as faulty on ebay. I've got the same one and it starts playing up where it will work, and sometimes it will then power off and free wheel. Not looked at the impact driver, but I did look at some replacement parts and as you rightly say the cost of them was nearly the same as a brand new tool making it uneconomical to repair unless you go down to component level.

[@WombleUK]

@@BuyitFixit I am going to get a rework station & have a go at replacing the mosfets myself. Even if it doesn't fix my saw I will still have the rework station for keeps, but if it fixes it I got the station & working saw again for probably £40 - £50 less than buying the replacement electronics element spare part. Can I ask what Temperature do you set your rework Hot Air to to remove & resolder the Mosfets?

[@BuyitFixit]

If it is one of the cheap ones like the 858D I'd use 450c. You might be better removing the board from the metal part of the motor like I just did on the "Hole Hawg" video I just did. It is pretty much the identical motor to the saw.

[@coreycarver9974]

Part numbers of replacement parts you used

[@BuyitFixit]

They are in the video Corey.. 5:55 12:37

[@coreycarver9974]

@@BuyitFixit thank you I found them. I really enjoy watching the Milwaukee videos it's very informative and it will be helpful if I ever have any problems with any of my Milwaukee tools

[@BuyitFixit]

You're welcome. Glad to help!