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DeWalt Are Stealing From You... Here's My Evidence

Doctor Lefthandthread

54,855 views

🔋 Welcome to an undisclosed location in County Tyrone!

Have your newer DeWalt XR 5Ah batteries started failing much sooner than the older ones?

After repairing power tool batteries for years, I've noticed a worrying trend. Batteries that once lasted four, five or even six years are now arriving on my repair bench after two years, and in one case less than a year old.

In this video I perform a complete battery autopsy, comparing an older 2016 DeWalt XR 5Ah battery with a much newer 2025 version to find out exactly what's changed inside.

During the teardown we compare:

✅ Old vs new DeWalt XR 5Ah batteries

✅ Battery management boards (BMS)

✅ Samsung 25R cells vs EVE cells

✅ Internal construction differences

✅ Real-world battery failures

✅ Why some newer batteries may not last as long

I also discuss published information about lithium-ion cell manufacturers and why premium brands such as Samsung, Murata and Panasonic have long-established reputations for consistency and quality control. I link the report discussed in this video in the description and pinned comment so you can review it yourself.

see below

https://www.prnewswire.com/news-relea...

This video is based on my own repair experience and observations from batteries that have come through my workshop. My aim is to explain what I'm seeing and encourage informed discussion among tool users.

If you've searched for:

DeWalt XR battery repair
DeWalt 5Ah battery failure
DeWalt battery teardown
DeWalt XR battery review
Samsung 25R vs EVE cells
DeWalt battery cells
Lithium-ion battery repair
Power tool battery repair
Why DeWalt batteries fail
DeWalt battery problems

...this video is for you.

👍 If you enjoy honest power tool repairs, battery diagnostics and detailed teardowns, please Like, Subscribe and let me know your own experience with the newer DeWalt XR batteries in the comments.

From an undisclosed location in County Tyrone...

I'm Doctor Lefthandthread... and that's my diagnosis.

#DeWalt #DeWaltXR #BatteryRepair #PowerTools #LithiumIon #18650 #Samsung25R #DIYRepair #RightToRepair #DoctorLefthandthread

20 Comments

@doctorlefthandthread Creator 1 month ago Pinned

Battery cell report
https://www.prnewswire.com/news-releases/study-reveals-1-in-13-low-cost-lithium-ion-battery-cells-could-have-dangerous-defect-302563908.html

@TWSmith42 1 month ago

'All fur coat and no knickers' ... love it!

@PedroMcMahon 1 month ago

You are correct. I noticed the drop in battery life as well

@MrKillswitch88 1 month ago

Half the time the issue can be fixed with balance charging but I've come across cells that not only leaked they were rusted through. A hidden danger is reverse charged cells. Better off just rebuilding the packs with new high quality cells and be done with it. For some packs it does get complicated particularly the 40v Ryobi batteries as there are no dedicated unlocking tools and one has to know how to reflash micro controllers to get the later models working. At least people have figured out Makita and thus have been able to build custom packs.

@metalscientistdude6076 1 month ago

Considering that DeWalt is the only brand that Stanley -Black & Decker hasn't ruined yet...this seems on point.

@waltp3373 1 month ago

These could be counterfeit batteries. It's hard to tell them apart. The counterfeits use subpar batteries. Watch the Project Farm video on that.

@jage6126 1 month ago

In Sweden we have 3 years "warranty" by law, so we can complain as soon as something looks suspicious with the battery.

@lbg2160 1 month ago

I got some relatively new batteries (less than 1 year) that I noticed started to fail on me. At the start I thought it was me. I haven't cracked them open but I'd say this is also the case. It's put me off buying anymore new batteries.

@masterserge 1 month ago

I've also noticed that the zinc strips are a bit on the thin side. For the price that we pay for Dewalt batteries, you would think they would use copper strips to connect the batteries together.

@sunejepsen 1 month ago

Good information!
Funny I got some EVE cells for a rebuild of some old Dewalt batteries (3ah and 2x1.3ah) 1 of 21 cells have failed after few time usage. Luckily it was in one of the 1.3AH, so it couldn't Drag its neighbor down with it and i only had 1 spare cell :)

@nvi0us 1 month ago

100 percent mate. I have had multiple original grey 54v 6ah flexvolt batteries last over 8 years. Now ive have two of the newer yellow 54v batteries dies in under 3 years. ALSO, the powerstack batteries.....almost pushed me to sell all my dewalt kits. Ive had 7 1.5ah power stacks since 2024.....i have one left that works. They all died the same, lights off, dead. No jump starting nothing.

@RonKris 1 month ago

I bought a new 5ah Dewalt battery last year, and as soon as I charged it, the power test lights came on, as they should, but never shut off. They continue to be lit as it sits there waiting to be used.

@jackipiegg 1 month ago

That's why I've been only buying aftermarket ones, they use eve cells too surprisingly.

@MrErViLi 1 month ago

pretty easy to modify any standard battery to fit any drill. or to just repair the battery yourself. it's usually just one of the cells. I have a drawer full of 18650, 21700, 30700, and 4680 cells I've pulled out of all sorts of battery powered devices. just open a failed battery and test the cells with a meter and swap out the bad one.

@dennyOfools 1 month ago

Very Informative, Thanks Doc. I'm sharing this.

@Vanman_fr 1 month ago (edited)

Dewalt usa has a string relationship with Samsung so they put Samsung in every pack they can even when is a significantly inferior cell compared to others like the Samsung 40t and 50e cells found in dewalts 8ah and 10ah packs. So I'll happily report all packs still have Samsung here in the states.

@nickwhitwham1762 1 month ago

I mainly use makita but have a couple of dewalt tools so I bought two of the new 5ah when they were offered cheap at screwfix. Im a bit of a sceptic at heart and remember opening the boxes saw they looked different and thought, this could be too good to be true I hope they last like the old ones 😂 and only yesterday i questioned them and then your video popped up today! The thought of them having subpar cells is concerning, might keep an eye on them when charging 🤔 im going open one up to have a look! Brilliant content and great video, I've like and subbed to say thanks, all the best 👍

@AdrianvanWijk 1 month ago

Dewily have rebranded the new round cell batteries, they're no longer XR and are now branded MAX. The XR batteries are the flat cell stack type. I guess that transition to cheaper cells happened before the rebranding. That said, I think Dewalt will just ignore this feedback because in their mind it's resolved with the branding.

@robertmorgan2145 1 month ago

The pack without the QR code is likely counterfeit. The project farm YouTube channel just did a report on counterfeit DeWalt batteries. Just about everything you buy on eBay now is counterfeit. And a lot of what Amazon sells as well.

@countrywideify 1 month ago

I have about 10 5 ah dewalt batteries. I have noticed for the last 2 years they have been loosing power quite fast , even my brand new ones. I seem to be charging them after about 20 mins of work. Especcially when using my grinder.