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FYI.. Lowes has the DW331K on sale right now for $149. Was $169...

I just spoke to a service center rep about this issue. Sometimes the blade clamp can get damaged when using orbital action in hard materials like Metal or hard wood, causing this problem. The service center can replace the clamp assembly for you, and that is the only way to fix the problem. They will also be able to tell if the problem was caused by missuse (using orbital action in metal) or if it's a manufacturer defect. That will determine whether it will be covered under the warranty or not. If it isn't under warranty then it should be under $40 to replace the front assembly.

I am not sure, just call up a Dewalt service center and ask them. They will let you know over the phone. Service centers can be found here: [url=http://www.dewalt.com/Find-Service-Center.aspx]http://www.dewalt.com/Find-Service-Center.aspx

I don't know about the charger, that would be a good question for MADTEC (I'm sure he will respond to this post) Seeing sparks in the vents is normal though, I wouldn't be worried about it.

No: http://dewalt.com/tools/cordless-drills-hammerdrills-dcd950kx.aspx

Just the look 950 comes with XRP NiCad Batteries, the 970 comes with the XRP Li-ion Batteries