MOTOR PUZZLE! Restoring A Hammer Drill Part 6 - Repairing / Rebuilding The SDS Chuck

Last time, as I was filming the cleaning / reassembly / testing of the hammer drill, I really thought I was done with this series and that the hammer drill had been fixed once for all... oh boy, was I wrong!
Just after switching off the camera, I had a little unfortunate surprise: when I tried to remove / release the drill bit by pulling on the rubber sleeve, nothing happened. The drill bit was locked and desperately stuck in the chuck. It could only be removed after a bit of bashing around. So, as an epilogue to fixing the hammer drill, today we will also repair its SDS chuck, and this starts by taking it apart to assess the problem before rebuilding it as it should have been in the first place...
Note:
* Since I have no history about that hammer drill, I'm not sure why the SDS chuck components were not mounted properly, but this is definitely NOT what would have gone out of the Bosch factory. This hammer drill has likely been built before the year 2000 (the price label refers to a currency no longer being used around here), so imagine someone tried his / her best to make it work without access to the amazing information on the internet. What the initial fault was that required the chuck to be taken apart in the first place, I can't say.
* If you are interested to learn about how an SDS chuck locking mechanism work, I have listed below the link to a separate video I made, also including links to the earlier episodes of our repair series..
► The previous episodes:
► How does an SDS locking / unlocking mechanism work?
• How Does A SDS Drill C...
► EPISODE 1: Checking For Completeness And Damage
• MOTOR PUZZLE! Restorin...
► EPISODE 2: Repairing The Broken Motor Brush
• MOTOR PUZZLE! Restorin...
► EPISODE 3: Removing Rust From The Armature / Stator
• MOTOR PUZZLE! Restorin...
► EPISODE 4: Cleaning / Polishing the Commutator
• MOTOR PUZZLE! Restorin...
► EPISODE 5: Final Cleaning and Reassembly
• MOTOR PUZZLE! Restorin...
► DISCLAIMER
Always make sure you operate in a safe and secure manner.
Since the SDS locking / unlocking mechanism is based on a floating metal ball, I'm also cleaning everything thoroughly to remove any gunk and debris that would interfere with the free movement of our ball. I'm not also not adding any grease, a personal choice, since it can mix with dirt and lock again the drill bit in place.
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[@sannekjer2820]

This is the 5th tile project we've done where we've removed the old tile before installing new tile, and the first one with this tool kzbin.infoUgkxqqoaX03nrziKwF7Bjjcc71YzLEleMvOS . I want to cry for all the unnecessary work we've done in the past. With this tool, we removed tile surrounding a fireplace, as well as the hearth tile, set in loads of cement, in less than an hour. I highly recommend this tool. It was easy to use, and very satisfying watching the tile literally fall off the wall.

[@TheLabOtomy]

Yep

[@EricGranata]

Glad to see it worked out.

[@TheLabOtomy]

And this time, no more surprise, project drill [completed] Felt I was changing onto a drill repair channel....

[@MalcolmJames-sg3zg]

There is a few videos on KZbin, But this is the best one to view THANKS

[@TheLabOtomy]

Good to hear, thanks

[@certuv]

Just the info I need. Thank you for posting

[@TheLabOtomy]

Welcome

[@ottofumbler7267]

Good tutorial. Although, it's made me realise I'm totally screwed. The BB in my chuck is jammed in the lock position, so I can't even get the bit out to repair it. I tried putting a pick on to the BB and hammering it down, but it won't budge. Oh, woe is me.

[@mweimorts]

Thank you for this video.

[@TheLabOtomy]

My pleasure!

[@nangarombabusy9790]

Your video is very useful for my machine repair thank you sir💐💐💐

[@TheLabOtomy]

Welcome!

[@Jsr735]

Such a nice video 📸 well explained

[@TheLabOtomy]

Thanks Jatinder

[@sisirachandrasena963]

Thank you for this video ,

[@TheLabOtomy]

Welcome Sisira

[@asaadengineer4631]

Well done ✅

[@TheLabOtomy]

Thanks

[@MN-qc1mw]

Fantastic

[@TheLabOtomy]

Agree

[@aamilhusain5196]

Very good 👍

[@TheLabOtomy]

Thanks

[@AerialLensVideo]

Great - Thanks! That looks like a Makita and no doubt the other major brands are the same metal washer ball capture design. Note the HF Bauer brand 1-1/8 SDS had a fatal flaw (in mine anyway), where there is not a washer but the sliding collar itself must do that job simply by being sized tight in that area, which wears easily (I guess that saved them 10 cents but ruined my unit's functionality after just a few easy hours). Lesson learned. Got a Makita now. Double the price but betting 50x tool life.

[@TheLabOtomy]

Thanks for sharing

[@powertoolsrepair]

Noce video and it's good that you show mistake found after fixing video 👍

[@TheLabOtomy]

Glad you liked it

[@asaadengineer4631]

I think you put the spring in different direction of the first time you opened it

[@RakibulIslam-uo2tu]

Very good

[@TheLabOtomy]

Thanks my friend

[@biomed2560]

Good demo of dismantling and reassembling an SDS chuck (bit too much of cleaning cloths flapping about). BUT what was the fault?

[@TheLabOtomy]

The issue was that the drill bit would stay stuck in the chuck every now and then... cause was the SDS chuck being rebuilt with parts in the wrong order... I do not know the history of the drill, so do not know why the chuck needing being taken apart and rebuilt in the first place...

[@rbsmanian729]

Very nice asssmbl....

[@anasca5258]

Thnks.. Use full vedio

[@TheLabOtomy]

Welcome

[@user-ps6ek4tp6w]

Thanks to your help I've managed to get the part and is now working. A shout out to 'Powertool Spares' for their help and swift delivery. Kind Regards.

[@TheLabOtomy]

Nice

[@ibrahimohammad1398]

Good

[@TheLabOtomy]

Thanks

[@Digitalhunny]

This music... 🤣🤣🤣When you strip to it.... it works _so_ well.🤣🤣🤣

[@TheLabOtomy]

Has been part of my routine for years...

[@Asadkhan-kn7er]

Sir my bosch hammer drill 2.26mm is bit wooble problem how can I solve this problem the bit cannot rotate strate please tell me what is the problem.

[@TheLabOtomy]

When this happened to me (to be seen in the video), the SDS chuck had been rebuilt but with components in the wrong order. So, first thing is to take the SDS chuck apart and see what is going on there. Any pieces out of place or broken can be the issue.

[@usmanali78602]

I love bro ❤

[@TheLabOtomy]

Thanks bro

[@user-ps6ek4tp6w]

Great video, thank you. I've been looking for a part to repair my SDS hammer drill I was wondering if you could advise me on getting a replacement? The item I'm after is the second item in from the right (a flat washer with a flange?) I don't the parts name , sorry. Any help with this would be much appreciated. I don't want to throw this drill away. Kind Regards.

[@TheLabOtomy]

Depending on the brand, the manufacturer may offer replacement parts (I recall seeing several SDS chuck replacement sets including rings, springs and metal balls). If it is not available, maybe some generic replacement part will work, so check the dimensions for compatibility.

[@user-ps6ek4tp6w]

@@TheLabOtomy

[@user-ps6ek4tp6w]

Good morning thank you for the quick response. The drill in your video was it a Bosch? The reason I ask is that the waster I'm after is exactly the same as the one in the video. I'm looking on line but can't find one to match. Kind Regards.

[@TheLabOtomy]

@@user-ps6ek4tp6w The drill in the video is a Bosch UBH 2/20 RLE

[@user-ps6ek4tp6w]

@@TheLabOtomy Thank you for the info. I'll email Bosch to see if they can provide me with a replacement washer. Kind Regards.

[@alexanderbendeli1557]

Great explanation as to its assembly and disassembly. Just banging the drill body on the bench was sufficient to somehow dislodge the balls to remove the drill bit. Once the SDS drill bit was removed and the rubber cover prised out, I just could not remove the circlip to release the spring and washer mechanisms. The circlip just keeps rotating around its slot as I try to prise it up with a wide screwdriver as per video. Is there a special tool to do that?? I think the lubrication grease (maybe there was too much) was preventing the balls from moving freely. As I could not separate all the chuck parts, I just immersed the front of the drill chuck & sleeve (less rubber cover) in a tub of mineral turpentine to hopefully dissolve the grease and make the parts clean enough so that the balls can move freely. Thanks anyway as I certainly gave me an understanding as to how the SDS mechanism works.

[@TheLabOtomy]

About the circlip, the one I found on the drill was pretty lose. I assume it had been already removed and some way bent to a wider diameter. For circlip removal, there are some specialized circlip pliers. I do not own one myself and do not think I will buy since dealing with circlip only one in a lifetime. About the ball being stuck, this is typical of this type of SDS design. Drilling creates dust (especially overhead drilling) which can mix with the chuck grease to create gunk that will keep the metal ball stuck... adding a vacuum and keeping the chuck clean is therefore important. In any cases, thanks for your feedback and good luck with your repair.

[@alexanderbendeli1557]

@@TheLabOtomy Hi, thanks for the personal response. I had used a 25mm drill bit and after use I could not remove it from the chuck. I eventually grabbed to bit in a vyce and kept banging and pulling the body away from the bit until the SDS bit was freed. I already have several circlip pliers, both for internal and external use. However, the "circlip" on my Ryobi SDS hammer drill is just a split ring. That is, maybe a 20mm circle with a 3mm section cut out and fitted in a slot on the arbor, there are no two holes on flat sections at the ends like a traditional circlip for the pliers to grip. There is no way to grip it and extract it, it just shifts about the slot irrespective which way I try to lever it out of the slot. I was able to insert the hard & sharp end of a scriber in a slot in the arbor to prise the clip out but all it does is to expand it slightly and push down rather than up. As mentioned, as I could not remove the chuck, I dunked the chuck section in a container of mineral turps to wash away grease and dust (not completely but enough). I sprayed some RP7 to clean the slot and balls and tested using another SDS drill bit (8mm bit). The 8mm SDS fitted and slipped in and out perfectly. Today, I refitted the 25mm SDS bit and drilled several more holes. Unfortunately, the same happened again. I banged the drill body, held the long 25mm bit in a vyce and just pulled back and forth until it came out. Upon cleaning the SDS shank I noted that one of the SDS slots on the shank had some deformation indents in it which may have caused one of the balls to "catch" and thus preventing the bit from being removed easily. Maybe the SDS drill bit shank has not been hardened and it possibly deformed during the "hammering" action of the drill. I will file these "burrs" and try again another day. Thank you for your help up to now. Cheers.

[@TheLabOtomy]

Thanks for the update, good to see folks with a problem solving mentality and skills!

[@rajayaqubkhan9908]

I have a makita Cordless Hammer Drill..Bit is broken inside.how to remove it please

[@TheLabOtomy]

Broken inside, if you cannot catch and pull on the bit (and remove it as it was unbroken), you may have to take the chuck apart...

[@danielsheltonmenezes8728]

I strongly feel that you should have lubricated at least the moving parts while reassembling.

[@TheLabOtomy]

Good point Daniel. I thought about it but decided to not add any grease at this stage (a personal choice) since greace can mix with dirt (especially when drilling overhead) and lock again the drill bit in place... greace can of course always get added later if things start to deteriorate... I'll monitor and act accordingly, but good catch, thanks for the feedback

[@thomascollyer3543]

My sds no won’t hold the bits in so when I go to use the drill it drops out

[@TheLabOtomy]

Definitely a ball issue

[@TheLabOtomy]

@@gringowars5125 If there is no damage to the ball and other parts, you can just reassemble the whole

[@TheLabOtomy]

@@gringowars5125 There are repair kits available, but any metal ball of the right diameter (see your product specs) will do

[@MrTucodj]

Excuse me, do you know where I can buy those balls that you have in hammer drill?

[@TheLabOtomy]

I would first check the manufacturer website for parts numbers and see what the web has to offer as alternatives qua pricing

[@gianrearte6634]

Location po

[@TheLabOtomy]

Yes

[@janindukaveesha9805]

Not

[@TheLabOtomy]

Not