Nothing stops a project faster than a broken impact driver bit stuck in the tool or your workpiece. But don’t worry there are simple ways to remove that broken bit and get back to work quickly. This guide provides step-by-step instructions for safely removing broken bits from your impact driver using common tools. It also includes tips to prevent future breakages.

Materials Needed

3M Safety Glasses – Essential eye protection from debrise them when they show signs of wear to avoid breakage. Drill Doctor Drill Bit Sharpener

IRWIN VISE-GRIP Needle Nose Pliers – Great for gripping small, hard-to-reach bits.

Neodymium Magnetic Hook Magnet – Perfect for retrieving small metal bits from tight spaces.

IRWIN Hanson Spiral Extractor and Drill Bit Set – Perfect for extracting broken bits lodged in materials.

WD-40 Penetrating Oil – Lubricant for loosening stuck bits.

Stanley 16-Ounce Hammer – For applying light taps to loosen jammed bits.

NEIKO 10037A Left-Hand Drill Bit Set – Helps unscrew broken bits with counterclockwise rotation.

MAGID T-REX Wear Safety Gloves – Protect your hands while working with sharp tools.

Step 1: Power Down and Inspect

Before starting, turn off and unplug your impact driver. If it’s cordless, remove the battery. Wear gloves and safety goggles to protect yourself from sharp edges or flying debris.
MAGID T-REX Wear Safety Gloves | 3M Safety Glasses

Check the bit to see whether it’s stuck in the chuck or embedded in the workpiece. This helps determine the best removal method.

Step 2: Removing a Broken Bit from the Chuck

If the bit is stuck inside the chuck, try these methods:

  • Using Pliers: Open the chuck as wide as possible. If part of the broken bit is exposed, use needle-nose or locking pliers to gently wiggle the bit and pull it out.
  • Using a Magnet: If the bit is too small to grip with pliers, use a strong magnet. Move it around the chuck until the metal bit loosens and comes out.
    Neodymium Magnetic Hook Magnet

If the bit is still stuck, you may need to disassemble the chuck. Refer to your impact driver’s manual for guidance.

Step 3: Extracting a Bit Stuck in the Workpiece

If the bit broke off inside the material, try these techniques:

Using a Left-Hand Drill Bit: Left-hand drill bits rotate counterclockwise, making them useful for unscrewing a stuck bit.

Using a Screw Extractor Kit: Apply some lubricant or penetrating oil to loosen the bit. Drill a small pilot hole into the broken bit, then insert a screw extractor and turn it counterclockwise to remove the bit.
Recommended Products: IRWIN Hanson Spiral Extractor and Drill Bit Set | WD-40 Penetrating Oil

Step 4: Use Light Hammer Taps

If the bit is jammed, tap gently around it with a small hammer. Be cautious, as too much force can damage your tool or project. Light taps create vibrations that loosen the bit, making it easier to remove with pliers or a magnet.
Stanley 16-Ounce Hammer

Step 5: Clean the Area

After removing the bit, blow away metal shavings with compressed air or use a soft brush to clean the area, ensuring your tool operates smoothly when you continue working.

Step 6: Prevent Future Bit Breakage

Here are some tips to avoid breaking bits in the future:

  • Use High-Quality Bits: Cheap bits break more easily. Invest in high-quality, impact driver-specific bits to reduce the risk of breakage.
  • Control Your Torque: Too much torque can snap bits. Adjust the torque settings on your tool to match the task, and avoid forcing the tool.
  • Replace Worn Bits: Worn or damaged bits are more likely to break. Regularly check your bits and replace any that show signs of wear, like rounding or chipping.
    DEWALT Impact Ready FlexTorq Bit Set

Final thoughts

Removing a broken impact driver bit can be frustrating, but with the right tools and techniques, it’s manageable. Whether the bit is stuck in the chuck or your workpiece, using pliers, magnets, screw extractors, or left-hand drill bits will help you safely remove it and continue your project without too much downtime.

Have you ever dealt with a stuck or broken bit in your impact driver? Share your experiences in the comments below! And don’t forget to check out my guide on the best bits for impact drivers to avoid these problems in the future.

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