collet won't release the bit, i press the release collar but the bit is totally stuck

Diagnosis

The failure of the collet to release the bit on the Milwaukee M18 Fuel 2953-20 is typically caused by "mechanical seizure" of the internal locking balls. In this tool, three spring-loaded steel balls push outward against the flats of a 1/4-inch hex bit to lock it in place. When you pull the release collar, it pushes these balls inward. If a tiny metal shaving, a grain of drywall dust, or a sliver of a stripped screw head has migrated into the collet housing, it acts as a wedge, physically preventing the balls from retracting even when the collar is fully depressed.

Another common culprit is "over-torque friction." If the bit was driven into a fastener and the tool experienced a high-torque kickback or a sudden jam, the bit can be forced deeper into the collet than intended, creating a friction lock between the bit's shoulder and the inner sleeve of the chuck. You can confirm this by pulling the release collar; if the collar moves freely but the bit does not budge, the issue is likely a debris jam or a deformed bit shank rather than a failure of the release mechanism itself.

How to Fix It

Since the tool is battery-powered, the first step is safety and stabilization to ensure you don't damage the internal drive train while attempting to free the bit.

1. Remove the M18 battery pack immediately to prevent accidental trigger pulls while your fingers are near the chuck.
2. Secure the tool in a vise by the metal gear housing (avoid clamping the plastic casing) or hold it firmly against a workbench.
3. Apply a high-penetrating lubricant, such as PB Blaster or WD-40 Specialist Penetrant, directly into the gap between the release collar and the chuck body. Let it soak for 5 to 10 minutes to migrate down to the locking balls.
4. Firmly depress and hold the release collar in the "open" position. While holding the collar, use a pair of pliers to grip the exposed end of the stuck bit.
5. Give the bit a sharp, quick twist (clockwise and counter-clockwise) while pulling outward. The twisting motion helps break the friction lock caused by the debris.
6. If the bit still won't move, use a small rubber mallet or a dead-blow hammer to gently tap the back of the tool's housing (the area behind the chuck) while keeping the release collar depressed. The vibration often jars the locking balls loose from the debris.
7. Once the bit pops out, use a can of compressed air to blow out the collet housing from the front to remove the metal shards that caused the jam.

If That Didn't Work

• The Thermal Expansion Method: Use a heat gun on a low setting to carefully warm the collet housing for 30-60 seconds. The heat causes the outer sleeve to expand slightly more than the internal locking balls, which can create just enough clearance to release a seized bit. Be careful not to melt the plastic housing or damage the O-rings.
• The Impact Shock Method: Place the tool (with the collar depressed) into a bench vise by the chuck. Use a hammer and a punch to deliver a sharp, controlled strike to the end of the bit, driving it further into the tool. This often "unseats" the locking balls from a debris-jammed position, after which the bit can be pulled out easily.
• Chemical Degreasing: If the jam is caused by thickened grease or construction adhesive (common in flooring or cabinetry work), soak the chuck area in acetone or a strong degreaser for 30 minutes. This breaks down the sticky residue that may be gluing the balls to the bit shank.
• Collet Replacement: If the collar no longer provides resistance (feels "mushy"), the internal return spring has likely snapped. In this case, the collet assembly must be replaced. This requires a full teardown of the front gear housing to replace the spring and ball set.

Heads Up

• Avoid using "impact-rated" bits that are slightly oversized or have poor tolerances, as these are more likely to wedge themselves permanently into the 2953-20 collet.
• Regularly blow out your chuck with compressed air after working in dusty environments (like masonry or drywall) to prevent the buildup of abrasive particles.
• Never use a hammer directly on the release collar, as this can bend the internal guide rails and permanently misalign the locking mechanism.
• Check your bits for "mushrooming" or deformation at the base; a bit that has been crushed by excessive force will not release and may require the chuck to be dismantled for removal.