Removing stuck drill chuck the hard way – cutting it with grinder

Recently chuck of my Skil hammer drill (Skil 6785 750w hammer drill) got stuck while drilling some concrete.

After some googling found few instructions how to remove stuck drill bit. But after removing drill bit I noticed that chuck itself is not functioning normally anymore. So it had to be replaced also. But after few failed attempts to unscrew the chuck it was clear that I will not be able to do that – its stuck like it was welded. Having no more ideas I took my grinder and decided somehow to cut the chuck out.

After the first attempt, I could remove most of the chuck parts, but still not able to remove chuck itself.

The second attempt – removed almost all of drill chuck, still no luck to unscrew it.

So decided to disassemble drill itself and see maybe I will get any ideas or better grip.

Removed shaft with the whats left of the chuck and gear.

After some more not so accurate cutting with a grinder and few hits with the metal punch finally I was able to unscrew the chuck from the drill.

Noticed that while cutting I have damaged threads of the shaft, but us chuck was unscrewing nicely I hope it will be no problem to screw in the new drill chuck.

Now the tricky part of assembling the Skil drill back into its original shape. Before putting the shaft back you have to insert small springy metal that pushes “lock” button. I was tricky to figure this out as when tearing apart this spring fell out and I had to think where it was originally by myself.

Another photo so you could better see where this spring has to be seated.

Then you put the shaft back.

Insert hammer/drill switch and “lock” button into their places.

And basically that`s it, you can put the cover back. Here, after a full inspection of the drill and checking that all functions work, I am measuring shaft diameter and length, just in case, as I’m now shopping for the new drill chuck for my Skil drill and hope that it will serve me few more years.

Update. After visiting hardware store I found out that chucks differ in thread type, so had to come back next day with the drill itself to test it.