Can Dewalt Batteries Have New Cells Fitted?

Repairs To Dewalt Nicad Rechargeable Battery Packs

A popular question by owners and users of Dewalt cordless power tools is can the Ni Cd battery backs be repaired and fitted with new cells?

The answer to this is Yes, but there are several considerations to be made before this is undertaken.

The first thing to consider is if the battery in question is still under any warranty or guarantee.

Brand new original Dewalt nicad batteries are covered with a 12 month warranty against faulty parts or workmanship. The manufacturers guarantee does not cover damage or faults which are due to accidental damage such as the power tool being dropped, and which results in a fractured battery casing or the internal cells weld in the pack breaking free.

If it is not under any form of warranty the next thing to consider is if it is economical to have the battery pack repaired.
The selling price of new original supplier Dewalt nicad batteries can depend on the voltage, the amp rating, the model number, and sales promotion that is in place at any one time. During particular seasons and months it is not unusual for Dewalt to run sales offers on different cordless power tools as well as their rechargeable batteries.

The cost of a new replacement pack should therefore be obtained, with perhaps quotes from several power tool dealers to compare.

Repairing And Fitting New Internal Cells

If the plastic casing on the faulty battery pack can be opened easily (most professional packs are held together with phillips or torx headed screws) then without a doubt new internal ni cad cells can be fitted. As long as the casings are intact the battery pack can have an indefinate life span.

If the pack is sealed there is no other option than to open it by way of carefully cutting the joints with a tool such as a dremel multi or similar. The casing afterwards would need to be glued or ultrasonically welded.

If you intend to repair the pack yourself establish if you have the knowledge, skills, and equipment necessary to complete the work. If you can open the dewalt battery packs casing you are half way there.

The next step is to identify and replace the internal cells. The nicad cells (the number of will vary depending on whether the power tool is 7.2v, 12v, 14.4 volt, 18 volt, or 24 volt) are available to buy individually from various suppliers and come in different capacity sizes.

The capacity size can mean the cell is smaller or larger in physical size and dimensions, so it is important to only buy cells that can fit into the battery packs plastic housing. If larger capacity cells can be fitted, this is a good option as it will give the relevant cordless power tool a longer running time when used.

The capacity size is measured in milliamps (mA). There are 1000 milliamps per amp so a standard 2.0 amp hour Dewalt battery may have the option of being upgraded to around 2.2 or 2.4 ah size.

Choosing Replacement Cells

When purchasing your new cells ensure they have the correct terminal types you require. Original equipment Dewalt Battery Packs are comprised of cells that are spot welded with metal connecting plates accross them.

Replacement "pattern" cells can be of this type or alternatively have connector lugs present to be used with either soldered wiring or solder joints. For the home repairer these last two types are best (as you most likely will not have a battery spot welding machine) being the easiest to fit.

The spot welded type however are of a stronger construction, being able to stand up to the rigours and expectations a portable power tool may be put to.

The rechargeable battery pack should be assembled in the same order it was dismantled with the plastic outer casings screwed or glued back together.

Finally the pack should be given a continuity test, and then given a complete charge cycle to condition the reconditioned battery up to full power.