Milwaukee Reciprocating Saw 6538-21-B36B (2010) Heat Sink Replacement

Introduction

You can use this guide to replace a damaged heat sink on a Milwaukee Reciprocating Saw 6538-21-B36B (2010).

If you are noticing your Milwaukee Reciprocating Saw is constantly overheating leading to reduced performance or efficiency, then you could have a problem with the heat sync. The primary function of the heat sink is to transfer the heat generated by the motor, which allows for the motors internal component to continue to work without the heat. Having a non-functioning heat sink can shorten the lifespan of the saw, as continued use with overheating and additional strain can accelerated damage to the saw. The heat sink reduces the risk of safety hazard posed by overheating as the saw could smoke and catch fire, while also decreasing the maintenance needed for damage caused by overheating.

As always, remember to unplug the saw before any replacements.

What you need

Step 1 Heat Sink

Milwaukee Reciprocating Saw 6538-21-B36B (2010) Heat Sink Replacement, Heat Sink: step 1, image 1 of 2

Milwaukee Reciprocating Saw 6538-21-B36B (2010) Heat Sink Replacement, Heat Sink: step 1, image 2 of 2

Use a T20 Torx screwdriver to remove the five 15.9 mm that fasten the two halves of the handle assembly together.
Use a T20 Torx screwdriver to remove the two 25.4 mm screws closest to the motor housing.

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Step 2

Remove the right half of the handle assembly.
Gently lift out the grey motor housing.
Take care not to strain the attached cables.

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Step 3

In this picture, the device does not have parts like the service armature, and the gearcase attached. These are not required to be taken off for this guide replacement.
Use a T10 Torx screwdrive to remove the single 22.2 mm screw that secures the heat sink.
Remove the heatsink.
The heat sink is attached with an adhesive and may require a little force to take off.