Replacing batteries in Black and Decker DP240 2.4V Direct-Plug Rechargeable Screwdriver

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I have owned a Black and Decker DP240 Cordless Electric Screwdriver for 5 years now. Its battery had started losing its capacity to hold charge, so I looked online to see if it was possible to change its batteries. I couldn't find any blog/DIY guide on which batteries to replace the internal ones with and how to go about pry open the screwdriver and putting it back. So here are some photos outlining how I changed the batteries in mine and turned it into new.

To open the screwdrive, you will need a set of "Torx Pin 6 lobe" screwdriver set. You cant use regular torx screwdriver bits. You need ones with holes in the center of the bits so that the center pin on the screw can fit into those holes. You can buy just a set of just the bits here.

Torx pin 6 lobe Screwdrivers to open the shell

Screwdriver with the shell opened

It seems that the screwdriver comes with two AA size
1.2V NiCd 800 mAh cells installed


I replaced the 800mAh batteries with 2550 mAh NiMH cells
eneloop by Panasonic is the best brand of NiMH cells


Soldering wires onto the cells

And putting the screw driver back together


Comments

  1. UnknownApril 14, 2018 at 8:52 PM

    How well did the NiMH cells work out? They usually require a different charging circuit.

    ReplyDelete
  2. Anurag ChughApril 15, 2018 at 11:20 AM

    Working better and lasting longer between charges than NiCd cells

    ReplyDelete
  3. SteveApril 9, 2021 at 2:39 AM

    I thought that the batteries might have been the problem on mine, but after taking it apart I found two issues. One the motor was seized. I simply added a few drops of oil to both sides, and it worked. Secondly while I had it apart I noticed a bad solder connection on the wire going to the motor housing.
    Also beware if you open it up the little gear on the end of the motor shaft can easily fall out (ask me how I know - heehee). And its not real obvious the chrome u-shaped metal clip has to come out to remove the gear assembly from the housing, easy once the screw and small black piece are removed.

    ReplyDelete
  4. GillesPDecember 1, 2023 at 5:44 PM

    Thank you for posting this. The torx with a hole in the center are called tamper proof. It took me awhile to figure out that after removing the small torx between the head piece and body the little plastic piece needs to be popped out so you can lift that metal clip out.

    ReplyDelete
  5. The EndJanuary 14, 2024 at 10:20 AM

    I'm about to take on this project. I ordered new nimh 1000mah batteries. Wish me luck. Thanks for posting.

    ReplyDelete
  6. BartmanEHApril 19, 2025 at 7:40 PM

    old blog post, I know :-) My B&D screwdriver came with 1200mAh batteries. The onboard charging circuit is 4 diodes arranged as a bridge rectifier for the AC input and 2 resistors... that's it! Can I safely recharge new replacement NiMH batteries with this simplistic charging circuit designed for the old NiCD batteries?

    ReplyDelete

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