Product Description
**Milwaukee parts change not only by model# but also by serial number. To look up your tools parts break down on Milwaukee's website please click here:
Milwaukee Tension Arm
Model Number: 42-09-0250
The Milwaukee 42-09-0250 Tension Arm is a genuine OEM replacement part designed for use on Milwaukee 1/2 in. Bandfile tools, including the popular 6101-6 corded Bandfile and related Milwaukee bandfile platforms that share the same head assembly architecture. The tension arm is the spring-loaded swing arm at the front of the bandfile head that holds the idler wheel against the abrasive belt, maintaining the proper running tension that keeps the belt taut, tracking correctly, and contacting the workpiece with the consistent pressure required for clean weld dressing, deburring, polishing, and finish grinding. As the operator depresses the tension release, the arm pivots inward to slacken the belt for changeover, then springs back to load the new belt under correct tension when released. Manufactured to Milwaukee's exact factory tolerances for proper pivot fit and spring engagement, this OEM tension arm restores correct belt tension, smooth release operation, and reliable belt tracking after wear, bending, or breakage of the original component.
Because Milwaukee Tool specifies replacement parts by both catalog number and serial number, always verify your tool's serial number against the official Milwaukee bandfile service parts diagram before ordering, since Milwaukee occasionally implements running production changes that affect part compatibility. The 42-09-0250 is the Figure 49 component on Milwaukee service bulletins 54-38-0828 and 54-38-0829 and works directly with the companion 42-09-0260 1/2 in. Contact Arm Assembly (Fig 50), which holds the platen and shoe that the abrasive belt rides against during use. When replacing the tension arm, Milwaukee recommends inspecting the contact arm assembly, dust cover (42-92-1200), support rod (45-60-0450), and 1/2 in. platen (44-66-5518) for wear at the same time, since these head-assembly components share the same service life and a tension arm failure is often accompanied by wear elsewhere in the head. All companion parts are sold separately. Verify by serial number using Milwaukee's online parts lookup before ordering to confirm correct fitment for your specific bandfile.
Features
- Genuine Milwaukee OEM replacement, direct factory part for the 42-09-0250 reference
- Designed for Milwaukee 1/2 in. Bandfile tools, including the 6101-6 corded Bandfile
- Spring-loaded tension arm holds the idler wheel against the abrasive belt for proper running tension
- Maintains correct belt tracking, tension, and workpiece contact pressure for clean abrasive work
- Allows tool-free belt changes via tension release lever operation
- Manufactured to Milwaukee factory tolerances for proper pivot fit and spring engagement
- Direct-fit replacement, no modification required for installation
- Restores correct belt tension and smooth release operation after wear, bending, or breakage
- Companion part: 42-09-0260 1/2 in. Contact Arm Assembly, sold separately, recommended for inspection at the same time
Specifications
- Manufacturer: Milwaukee Tool
- Part Number: 42-09-0250
- Official Description: Tension Arm
- Component Type: Bandfile Belt Tension Arm
- Primary Fitment: Milwaukee 1/2 in. Bandfile tools
- Confirmed Compatible Model: 6101-6 Corded Bandfile (878F variant)
- Service Bulletin Reference: 54-38-0828 and 54-38-0829, Figure 49
- Belt Compatibility: 1/2 in. width abrasive belts
- Quantity: Sold individually, 1 arm per order
- Part Type: OEM Service Replacement Part
Includes
- (1) Milwaukee 42-09-0250 Tension Arm
- Note: 1/2 in. Contact Arm Assembly (Milwaukee 42-09-0260) is NOT included and sold separately
- Note: Dust cover (Milwaukee 42-92-1200), support rod (Milwaukee 45-60-0450), and 1/2 in. platen (Milwaukee 44-66-5518) are NOT included and sold separately
- Note: Tension spring, knob (Milwaukee 43-98-0700), nut (Milwaukee 05-55-0116), and clamp screw (Milwaukee 45-04-0015) are NOT included and sold separately
- Note: Abrasive belts are NOT included — select the correct 1/2 in. belt grit and length for your application
- Note: Verify your tool's catalog number and serial number against the official Milwaukee parts diagram before ordering
