Milwaukee Reciprocating Saw Repair – Replacing the Power Cord (Milwaukee Part # 22-64-1627)

30November 2021

The cord is a two wire 18 gauge cord. Power cords tend to receive lots of abuse. The cord can be cut, nicked, internally damaged,
or have the proms broken off. A damaged cord should be immediately replaced
to avoid an electric shock. Replacing the cord is a repair that you can
do yourself and I'm going to show you how.Advertisement: Hi, I'm Mark Sodja. Do it yourself repairs like these are easier
than you might think. From lawn machines to cordless drills, kitchen
mixers, outdoor grills, our how-to videos walk you through each repair from start to
finish, so doing it yourself means never having to do it alone. Let's get started.Mark: I'll begin by removing
one half of the rear handle.

Now, I'll remove the screw that secures the
switch. I'll pull the switch away from the housing. This style of switch uses a connector called
a trap door. To remove the wires, I'll use a T-pin, insert
it next to the wire that will release the connector, and then I can pull away the wire. Now, I can remove the cord. I'll remove the strain relief from the cord.Now,
I can install the new cord. First, I'll need to prep the wires. I'll start by stripping back about a quarter
inch of insulation from each one. I'll twist the strands. Now, I need to tin the wires, that is to apply
a little bit of solder to each wire to make it solid so I can insert it into the switch. The first step in tinning is to apply a little
flux to each of the wires. This will make the solder flow easier. I have a small vice I'll use to secure the
wire. This will make it a little easier to solder.I'll
heat the wire and then apply the solder, and now the other wire.

I'll reinstall the strain relief, and I'll
reinstall the strain relief and cord into the housing. To install the wires into the switch, I just
simply push them into the connectors. Then I'll reinstall the switch into the housing,
secure it with a screw, and I'll make sure all the wires are tucked out of
the way. I'll finish up by reinstalling the handle.Now, you can replace the cord in your power tool.Advertisement:
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