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Assuming that the drill is still operating, I suggest that you get a replacement chuck, To remove the old chuck, insert the chuck key in the cogs on the left hand side as you hold the drill facing outwards, then using a hammer tap the chuck key firmly so that the chuck will revolve anti clockwise. Replacing the chuck us the reverse of the above procedure.
Open the chuck wide open. In the center is a retaining screw, they usually have left hand threads. Remove the screw. Take an allen wrench1/4" to 3/8" in size and fasten the short side tightly in the chuck. The chucks are usually right hand thread, so take a small hammer and strike the allen wrench to turn the chuck to the left to loosen it. Once you have the chuck off, verify the thread size of the drill motor shaft, then go to McMaster-Carr and choose the one you need.
The chuck can be removed and replaced with a new one. Unplug the drill. Insert a 5/16 in. or larger hex key into the chuck of the drill and tighten the chuck jaws securely. Tap the hex key sharply with a mallet in a clockwise direction. This will loosen the screw in the chuck for easy removal.
Insert the hex key into the chuck and tighten the chuck jaws securely. Tap sharply with a mallet in a counterclockwise direction. This will loosen the chuck on the spindle. It can now be unscrewed by hand.
Take digital photos when taking the front metal gear box off the drill. Next carefully remove the two plastic halves of the drill if needed to gain access to the shaft that holds the chuck.
Replace the broken threaded metal part that the chuck screws onto.
Normally chuck replacement involves unscrewing the small screw deep inside the chuck on a metal shaft has a left hand thread. Next use a large allen wrench tightened in the chuck with a mallet to loosen the bad chuck. Reverse to install new chuck.
If the chuck is stuck open and you cant "muscle" it closed something is probably jammed up in there and it needs to be replaced. Chucks take a good share of the abuse on power tools and most manufactuers consider them a "common wear item" like brake pads or Tires on your car. A chuck is fairly simple to replace if your drill stuck open and they are commonly replaced on the higher end "Industrial Grade" Power Tools like DeWalt and Milwaukee.
Looking at the Make and Model of your drill it would probably be easiest and most cost effective to just replace the entire drill. If you tried to replace the chuck and found a chuck that will fit your tool it may cost you anywhere from $25 - $40. For Around $40 you can purchase a new drill with a fresh battery.
The chuck is screwed on with RH threads. Lock the shaft and insert your chuck key into one of the key holes. using a plastic or wooden mallet give it a sharp tap in the right direction, this should free it up so that you can remove it. When you reinstall the new chuck us the same method to tighten the new chuck.
Depending on the size and manufacturer of the chuck a replacement should be between $35 and $50. You can replace it yourself by following the instructions on the new chuck. It's not very difficult and you can probably get the replacement at most Big-Box hardware outlets.
I have a DC927 and a DC926 that I removed 1/2" Rohm Supra SK key-less chucks on. This process is pretty simple. Put the drill motor in 1st gear. Put the clutch ring in drill mode and not in driver or hammer. Reverse or open the chuck all the way. Hold the chuck firmly in a vise and give the drill a good POP counter clockwise. The last step can also be done with a pipe wrench by placing the drill on a work bench and turning the chuck counter clockwise. Continue to un-thread until the chuck is removed. The replacement chuck must have the same mounting process and mechanism. Put a few drops of locktite on the threads and thread the replacement chuck back on. Tighten the chuck using the vise or pipe wrench. Place the short end of an allen wrench in the chuck and tighten down on it. Placing the drill on a work bench, strike the allen wrench with a mallet to finish tightening and locking down the chuck. Congratulations, you have just changed out your chuck.
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