I thought I broke my 18 volt masonry drill mixing grout years ago. Then it started smoking a little bit and after I let it cool down it kept smoking more and more so I just stopped using it. Fast forward 4 years while it was collecting dust and I thought I should take the time to sort it before it ends up in the trash. I watched a few YouTube videos from Backstreetmechanic (search "dewalt cordless drill repair, SMOKING MOTOR!") and decided to give it a try. I just cleaned the motor (1:20 min is the 5 minute mark in his second video), replaced the brushes and repaired! $15 + 30 minutes to fix a $200 drill. It was worth it. What I've learned is that dirt between the motor and the brushes or just old, worn brushes can create a lot of friction between the brush and the motor. If squeezed uncontrollably and hard, the brushes and motor will heat up to the point where they will start to melt (hence the smoke). If they merge together, you're probably SOL, but if you can spot it early, this process can get your drill working again.
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