Whats The Secret....

Yes, CCW.

If you don't have enough leverage, get a larger wrench and/or a longer cheater pipe. Seriously, if the chuck is small enough and isn't a drill chuck, you can try using a strap wrench around the chuck body, if you have one large enough and sturdy enough. The reason for limiting the size of the square or hex stock to what will just fit through the chuck body is that part of the jaw is always "down inside" the chuck body. With square stock and maybe with hex, you can turn part of the corners off of the part down inside the chuck in order to have a larger socket or wrench on it.

The reason for suggesting the set screw loosening and re-tightening step is that there is always a little play or clearance between the key and the slot in the bull gear. The suggested procedure ensures that you start off with the key firmly against the side of the slot that you are going to be pulling against.
 
Interesting thread- I guess there are folks who use the same chuck forever, for every job, hence the 50 year stuck.
Probably a good thing to add to anyone's used lathe evaluation: does the chuck come off easily?
-Mark
 
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