How To Replace Old Dewalt Cordless Drill Battery Cells

Why Should You Replace Power Tool Battery?

Batteries for power tools can often be repaired by replacing one or all of its battery cells. Replacing battery cells is a good option if you want to save money, as purchasing a new battery is more expensive than replacing the battery cells. If you intend to replace your battery cells, it is important to take note of the steps and guidelines to make the task easier. Here are the steps involved in replacing Dewalt battery cells for your cordless drill tools:


Step 1: Take The Battery Apart

The first step that you need to do is to take apart the battery pack. Visually inspect the battery pack to determine how to take this apart. You simply have to remove six hex screws that hold the battery pack together.

Once the screws are removed, you need to pull apart the two halves of the pack carefully. While doing this, you should take note how they go back together. A good way to do this is to use a digital camera to document the disassembling process.

Step 2: Remove The Battery Pack

For the second step, you need to pull the battery pack out of its holder carefully. While doing this, you should also take note how things are placed. You have to document everything to make sure that you can review it when you start assembling the battery pack with the new set of battery cells. You should draw or take pictures to note how the batteries are packed and connected to each other.

Step 3: Shop For Battery Cell Replacements

Once you have disassembled the pack, the next thing that you need to do is to shop for replacement batteries. You should make sure that the replacement batteries that you purchase are of the same kind as to the original ones. This way, there will be no issues when you install them. You should measure the battery cells to make sure that you purchase the correct size.

Step 4: Diagram The Connections

The next step involves connecting the battery cells together. You should check the original pack for this and base the connections on how it is initially connected. You need to take note of the wiring connections. A good way to do this would be to draw a diagram showing the top and bottom connections. It is also recommended that you place numbers on the batteries for easier identification.

Step 5: Creating The Battery Tabs

The next step involves creating the battery tabs. The battery tabs must be flexible. You can use a computer cable that comes with an outer mesh for this. The mesh can be squashed flat and soldered onto the batteries. Count the connections you need to make to determine the number of strips that you will need for this.

Step 6: Preparing The New Batteries

Once you have prepared all the materials you will need to prepare your new battery cells, you can start connecting them. Use a soldering iron for this and make sure to wear the eye shield for protection. It is also important to take caution in handling the soldering gun. You have to make sure not to overheat the batteries. Take your time and arrange the cells according to how the original one looks like. You should check your diagram as well.

Step 7: Assemble The Battery Pack

Once you have the new battery cells in position, you can start assembling the battery pack. You can check your documentation in the disassembling process.

Step 8: Testing After Charge Your New Battery Pack

Once done, you can charge your new battery pack. If you have set everything correctly, there should be no problem with your new set of battery cells. Plug in your power tool and test running; You can unload testing. If it does not have anything abnormal, it's ready to use.

Replacing battery cells instead of purchasing a new battery pack is definitely less expensive and more convenient for those who wish to save some money. However, it is critical that you take caution in doing the steps and make sure that you complete the steps without shortcuts. This way, your new battery pack will work just fine.

Last Updated on

Jose A. Brown

Jose A. Brown is a mechanic engineer and an enthusiastic blogger whose mission is to provide the readers with the best tips, guides in the Home Improvement, DIY Project, and Industry.

Click Here to Leave a Comment Below 0 comments