No matter which power tool brand you’re looking at, the switch to cordless, battery-operated tools has been done with convenience in mind. Without cords and plugs, tools can go more places and are far more maneuverable than they were previously. When a battery needs to be charged, it is simply removed from the tool and attached to a charger for however long its charging will take. While this process is usually trouble-free, even with one of the biggest brands in power tools like DeWalt, the seemingly straightforward action of removing a battery from a tool can go wrong.
If you want to free a stuck battery from a DeWalt tool, first and foremost, try using the release mechanism. Push down on the button and slowly pull and wiggle the battery to try and get it out. It might be tight, but ideally, the side-to-side movement will loosen whatever is stuck inside the track that’s preventing the battery from leaving. If it won’t budge, adding a little bit of silicone spray to free the connection could help get the tool and battery separated again.
If that doesn’t work, attaching a wood shim to the bottom for protection, holding onto the tool in one hand and the battery in the other — pressing down on the release button — and tapping it on a hard surface in the direction it’s supposed to slide out of the tool should get it moving. While getting stuck isn’t one of the most common DeWalt battery problems, it undoubtedly happens. Thus, one has to ask, why is this a concern at all?
Causes of DeWalt batteries getting stuck inside tools
If you’re dealing with a DeWalt battery that is currently stuck or has been previously in a tool, there are several factors to investigate. The first is the release mechanism, since this is the element behind the battery clicking into various tools and staying there securely. If it’s broken or packed with debris that prevents it from locking and releasing freely, it should either be thoroughly cleaned with compressed air or the battery should be replaced entirely. Theoretically, it is a part that can be replaced if broken, but the dangers of opening the casing of a lithium-ion battery are too great to justify this type of repair. This could cause flames or small explosions as volatile elements are exposed.
It’s also possible that another part of the battery, the terminals, is to blame. These are the metal strips that make contact with the tool once the battery is locked into place. If they’re warped or misaligned for one reason or another, or jammed up with dirt and dust, they can hold on to the tool too tightly and make removal a struggle. This is another situation where battery replacement may be needed if cleaning with compressed air or a cloth doesn’t work. Internally malfunctioning batteries may bulge as the internal chemicals break down, potentially making the battery too big for the locking mechanism.
It’s inevitable that over time, DeWalt batteries will break down in multiple ways. While it’s technically possible to refurbish DeWalt batteries, the risks are just too high. If you’re dealing with units that you’ve repeatedly had to go to great lengths to remove, it might be time to look into replacements for your convenience and safety.
