Milwaukee Surge Problems : 5 Common Issues (Solved)

The Milwaukee Surge is a powerful and versatile power tool that is widely used in various industries, including construction, woodworking and vehicle repairs. With its compact design and advanced technology, it has become a favorite among DIY enthusiasts alike. The Milwaukee Surge is known for its ability to deliver trustworthy performance and efficiency. But this does not mean that the Milwaukee Surge doesn’t have problems that can hinder its performance, and today, we’ll be looking at exactly what those problems are and how to solve them. Let’s find out more.

Table of Contents

What Is The Milwaukee Surge?

The Milwaukee Surge is a cordless hex driver that is part of the M18 Fuel lineup. It is designed to provide maximum power and performance for a wide range of applications. The Milwaukee Surge hex driver is equipped with a hydraulic drive system, which delivers 50% quieter operation and 3× less vibration compared to traditional impact drivers. This makes it an ideal choice for professionals who need to work in noise-sensitive environments. The Milwaukee Surge hex driver also features Milwaukee’s patented Powerstate Brushless Motor, which delivers up to 30% faster driving speed and 4× more runtime than competing models. This ensures that you can complete your tasks quickly and efficiently without worrying about running out of battery power.

Milwaukee Surge Problems

1. Battery Life Problems

One common issue that users may encounter with the Milwaukee Surge is a shorter battery life than expected. This can be frustrating, especially when working on large projects or in remote locations where access to power outlets may be limited. This problem is usually due to;

  • Depleted battery capacity
  • Prolonged overusage

Troubleshooting Battery Life Problems

  • Check the battery capacity because over time, batteries can lose their ability to hold a charge effectively. If you notice a decrease in battery life then it may be time to replace the battery.
  • You should avoid using the highest power setting, as higher power settings can drain the battery more quickly. Also ensure that the hex driver is not left on when not in use, as this can also contribute to a shorter battery life.
  • Be sure to regularly clean the battery and ensure that it is kept dry because moisture or dirt on the battery terminals can interfere with the flow of electricity and reduce battery performance.

2. Overheating Problem

Another common issue that users may face with the Milwaukee Surge is overheating. This can occur when the hex driver is used continuously for an extended period or when it is subjected to heavy loads. The problem can also be caused by;

  • A blocked ventilation system
  • Faulty accessories

Troubleshooting The Overheating Problem

  • You should always avoid using the power tool continuously for long periods without breaks. If you notice that the Milwaukee Surge feels excessively hot then you need to stop using it and allow it to cool down before continuing.
  • You may also have to inspect the power tool regularly and clear away any debris or obstructions that may be obstructing the airflow. This will help to keep the hex driver cool and prevent overheating.
  • Ensure that you are using the appropriate accessories for the task at hand. Using accessories that are too small or too large can cause the hex driver to work harder than necessary and then leading to overheating.

3. Chuck Jamming Problem

Some users may experience issues with the chuck jamming on their Milwaukee Surge. And this can be nothing short of frustrating, as it prevents the user from being able to change bits or attachments easily. This issue is usually caused by;

  • A dirty chuck
  • A dried out chuck
  • Worn-out chuck parts

Troubleshooting The Chuck Jamming Problem

  • You have to use a soft brush or cloth to clean the chuck, removing any dirt or debris that may be causing the jamming and avoid using water or harsh chemicals, as these can damage the Milwaukee Surge.
  • Also apply a small amount of lubricant to the chuck can also help to prevent jamming and use a lubricant that is specifically designed for power tools and apply it according to the Milwaukee Surge’s instructions, as this will help to ensure smooth operation of the chuck and prevent jamming.
  • Inspect the chuck carefully and look for any signs of wear or damage and if necessary then you need to contact Milwaukee’s customer service for assistance with replacing any worn or damaged parts.

4. Excessive Vibration Problem

Excessive vibration can be a problem for some users of the Milwaukee Surge. This can make it uncomfortable to use and may affect the accuracy and usability of the power tool. It is usually caused by;

  • Loose screws or fasteners
  • Damaged internal components

Troubleshooting The Excessive Vibration Problem

  • Inspect the power tool carefully and tighten any loose screws or fasteners that you find as this will help to reduce vibration and improve the overall performance of the hex driver.
  • If you find that excessive vibration is still an issue then you may need to consider using anti-vibration gloves. These gloves are specifically designed to absorb and dampen vibrations thus providing a more comfortable and controlled grip on the Milwaukee Surge.
  • It may also be necessary to contact Milwaukee’s customer service. They will be able to provide guidance and assistance in troubleshooting the problem.

5. LED Light Malfunctioning

The Milwaukee Surge features an LED light that illuminates the work area, providing better visibility in low-light conditions. However, some users may experience issues with the LED light malfunctioning. And it is usually due to;

  • Faulty battery connections
  • A dead LED bulb

Troubleshooting The LED Light Malfunctioning Problem

  • The LED light is powered by the Milwaukee Surge’s battery and if the LED light is not functioning properly then you need to check the battery connection to ensure that it is secure.
  • If the battery connection is secure and the LED light still does not work then it may be necessary to replace the LED bulb.
  • If the LED light issue persists, despite trying the above solutions, it may be necessary to seek professional assistance therefore you should contact a certified Milwaukee service center or a qualified technician who can diagnose and repair the problem.

How To Prevent Problems With The Milwaukee Surge

  • Always keep the Milwaukee Surge clean after every use to decrease the chances of problems due to clogging like the chuck jamming problem.
  • Be sure to regularly lubricant the power tool to improve the overall usability and avoid unnecessary jamming that will hinder the power tool’s performance.
  • Make sure to keep your work area clean.
  • Use only the recommended accessories from Milwaukee to avoid damaging the hex driver.
  • Always use the power tool with a fully recharged battery to avoid blowing a fuse and thus damaging the power tool.

Can I Use The Milwaukee Surge for Heavy-Duty Applications?

Yes, the Milwaukee Surge hex driver is designed to handle heavy-duty applications. It is equipped with a robust motor and advanced technology that allows it to deliver maximum power and performance. However, it is important to use the tool according to the manufacturer’s guidelines and not exceed its recommended usage limits.

Can I Use Non-Milwaukee Accessories With The Milwaukee Surge Hex Driver?

While it is possible to use non-Milwaukee accessories with the Milwaukee Surge hex driver, it is recommended to use Milwaukee accessories for optimal performance and compatibility. Non-Milwaukee accessories may not fit or work properly with the tool, which can affect its performance and potentially cause damage.


The Milwaukee Surge is a reliable and high-performance power tool that is designed to tackle a wide range of tasks. While it is a durable and well-designed tool, users may occasionally encounter problems or issues that require troubleshooting. Remember to always refer to the manufacturer’s guidelines and seek professional assistance when you need it. With proper care and maintenance, your Milwaukee Surge hex driver will continue to deliver exceptional performance and help you complete your projects efficiently and effectively. So you may want to invest in this powerful tool and experience the difference it can make in your work.