A Complete Milwaukee Sawzall Troubleshooting Guide

milwaukee sawzall troubleshooting guide


Milwaukee Sawzall is used for cutting, pruning, and demolition tasks, and it is commonly used in the construction industry. It also often causes problems and issues. 

And that’s where the Milwaukee Sawzall troubleshooting guide comes in. 

A Milwaukee Sawzall is a powerful tool that might cause issues with improper use. First, check If the blade is jammed, you might wanna apply some grease inside and clean it. But if that’s not the case, you’ll probably be looking at more concerning issues.

Since Milwaukee Sawzalls are tricky tools to fix, follow the article to find out more about the troubleshooting details. 

Milwaukee Sawzall: A Troubleshooting Guide

Milwaukee M18 Fuel Sawzall with One-Key

Source: protoolreviews

Let’s have a quick look at the symptoms and solutions. 

Problems Symptoms Solution
Sawzall is not starting Faulty power source, detachable power cord and trigger switch.  Check power source.

Plug battery for charging. 

Check trigger switch. Replace quik-lok cord. 

Or replace failed trigger switch. 

Overheating Battery failure or complete shutdown. Turn Sawzall off and let it cool. 

Use right blade.

Grease and clean the tool. 

For battery issues, reset or replace it.

Blade Issues Dull blade, wrong blade, blade jammed, bent, damaged, or broken blade, too much vibration.  Insert the blade properly.

Use the right blade.

Replace the damaged, bent or dull blade. 


Problem 1: Sawzall Is Not Starting


  • An error in the power source. 
  • Quik-Lok cord issue.
  • An error in the trigger switch. 

Solution 1

For a power source issue, check first. Here’s how to check it. 

Step 1: Turn off the Sawzall.

Step 2: Locate the power cord or battery pack.

Step 3: For corded Sawzalls, check the power cord for damaged or frayed wires and replace them accordingly.

Step 4: For cordless Sawzalls, check the battery charge level and charge it using the proper charger.

Step 5: After a full charge, connect it to the Sawzall. Then, turn on the tool and check if it runs. 

Step 6: If it does not run, test the battery pack using a multimeter for the correct supply voltage. 

Step 7: If it’s on the correct supply voltage, then Sawzall itself might be the issue and need professional diagnostics.  

Solution 2

For a problem with the Quik-Lok cord, you need to replace it. 

Source: Amazon

To replace the Quik-Lok cord in a Milwaukee Sawzall, follow these steps:

Step 1: Turn off the Sawzall.

Step 2: Locate the Quick-Lok cord connector. 

Step 3: Press the release button to release the Quick-Lok connector.

Step 4: Pull the Quick-Lok connector away from the Sawzall.  

Step 5: For removal difficulty, fully depress the release button without damaging the tool or connector. 

Step 6: Now, insert the new cord connector into the port. 

For your convenience, here’s a visual guide. 

TOOL REPAIR | Milwaukee Quick Lock cord & Sawzall Brush Replacement

Problem 2: Sawzall Overheating


  • Lack of lubrication. 
  • Faulty battery
  • Excessive pressure. 
  • Wrong use of extension cords. 
  • Overuse. 
  • Worn out over time. 

Solution 1

Disassemble the Sawzall and apply proper lubricants to the gear and shaft connection point. You’ll need a multi-bit screwdriver, needle nose pliers, and magnetic pickups to disassemble the Sawzall. 

milwaukee sawzall troubleshooting guide

Source: lovemon.

Make sure to unplug it from the power source. Then clean the tool then apply lubricants if required.

Step 1: Grab and peel off the rubber cover to access the inner screws. 

Step 2: Start loosening up each screw from one end using the multi-bit screwdriver. 

Step 3: Start removing the parts using either a needlenose plier or magnetic pickups. 

Step 4: Now, remove the cover completely. 

Here’s a video to help you disassemble the tool. 

Tool Tear Down: How to Disassemble a Reciprocating Saw | eReplacementParts.com

Step 5: Use damp cloths and mild soap for cleaning. 

Step 6: Now, apply Milwaukee type B grease to the power head. 

Step 7: After lubrication and cleaning, reverse steps 4 to 1 to reassemble the tool. 

Solution 2

Follow these steps to remove the battery pack:

Step 1: Locate the battery’s release buttons. 

Step 2: Press and hold down the release buttons.

Step 3: Holding down the release buttons, pull the battery pack’s bottom away.

Step 4: After the battery unlatches, release the buttons.

Step 5: Now, remove the battery pack. 

Now, for a hot battery, it needs replacement. And if it’s not hot, clean the battery connection using 2/3rd bicarb soda and 1/3rd water. 

Now, try resetting the battery. 

Step 1: Place it on a proper Milwaukee Sawzall charger and connect the charger to a power source. 

Step 2: Connect the battery. 

Step 3: Wait a couple of minutes for charging to come through. If the pack fuel gauge light of the battery shows the remaining battery charge before shutting down and resetting, it is reset. 

If resetting doesn’t work, replace it. 

Step 1: After removing the battery, insert the new battery by holding the release button. 

Step 2: After inserting the battery, the latch will be fastened with a click sound. Now, make sure the battery pack is properly inserted before letting go of the release buttons. 

Problem 3: Blade Issues


  • Dull blades
  • Damaged blades
  • Jammed or bent blade
  • Wrong blade for the cutting material
  • Too much vibration 


For a jammed blade, clean it with WD-40 to free up the collar. For bent or damaged blades, you need to remove and replace them. The reciprocating saw blade wobbles because of a bent blade. 

Tools needed

  1. Needle-nose pliers. 
  2. Compressed air. 
  3. A brush.

Precaution: Make sure to turn the Sawzall face-down and wear protective gloves. 

Step 1: First, remove the battery pack and wait for 5-10 minutes.

Step 2: Blow compressed air and clean the collar using a brush. 

Step 3: Twist the collar to the right. Now, press the tool body against the flat surface. 

Step 4: Grab the blade with a needle-nose plier. Then, pull it out of the Sawzall. Then, release the collar. For broken or damaged blades, use thin metal cutting blades. 

Step 5: Now, lose the lever and insert the new blade into the open socket. 

Step 6: Lower the collar until the blade’s in its place securely. 

Here’s how to do it if you need visual assistance.

Quik-Lok Blade Change – Milwaukee M18 FUEL 2720-22 Sawzall

Now, if you have a Milwaukee Drill, see Milwaukee Drill chuck problems to have your questions answered.


What Lubricants Should I Use on My Sawzall?

The type of lubricants you should use on your Sawzall are WD-40, SAE 10 or 20 oil, bar oil, high-temp chassis grease, Moly CV joint grease, etc. Clean the blade and collar after a heavy cutting application to keep the tool in good shape. 

How Fast Is A Milwaukee Sawzall?

The Milwaukee Sawzalls are pretty fast with a trigger speed of 0-3000 strokes in a minute. The Milwaukee Sawzalls are coming in new forms with increased speed, durability, ergonomics, and power. 

How Many Watts Does A Sawzall Pull?   

A Sawzall usually pulls approximately 500 to over 1000 watts. As the Sawzalls come with increased durability and speed in every update, the power it pulls also varies based on the amps used. 


So, now you’re equipped with all you need to know about the Milwaukee Sawzall troubleshooting guide. It is time to fix the issues you’re having with the tool and get to your garage. 

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