How to Replace the Brush Cap on a DeWALT Angle Grinder (Model D28402)

If broken parts and faulty starts are grinding on your nerves, it's time to face the fix. Whether you are a grinding pro or seasonal grinder, eReplacementParts.com provides the parts, procedures and facts you need to fearlessly fix what fails you.

The brush arm cap holds the brush arm assembly (including the arm and the felt seals) in place on the grinder. Typically, this component won't fail on its own. The most common reason for replacing the cap is that it becomes damaged (or lost) during related service procedures. This article provides step-by-step instructions for replacing the brush arm cap on a DeWALT D28402 grinder. Let's get started.

  REMOVING THE BRUSH CAP [top] 1. Remove the top half of the handle assembly.

Remove the (5) retaining screws.

Remove the top half of the handle assembly.

  2. Separate the handle from the field case.

Remove the paddle assembly.

Remove the lock-on button assembly.

Separate the handle from the field case.

  3. Remove the brush cap.

Use long-nosed pliers to remove the brush wire from the terminal.

Use long-nosed pliers to lift the brush spring away from the brush arm.

Lift (rotate) the brush arm assembly to access the brush.

Remove the brush from the arm assembly.

Remove the brush arm retaining screw.

Remove the brush arm cap.

  INSTALLING THE NEW BRUSH CAP [top] 4. Install the brush cap.

Install the new brush cap onto the brush arm assembly. (Notice that the brush cap on the reverse side of the grinder is installed.)

Secure the brush cap (and arm) with the screw.

  REASSEMBLING THE UNIT [top] 5. Reinstall the brush.

Insert the brush lead (wire) through the opening in the brush arm.

Seat the brush into the brush arm assembly.

Lower (rotate) the brush arm assembly into position above the armature.

Reinstall the brush wire.

Use needle-nosed pliers to re-engage the brush spring.

  6. Reconnect the handle assembly to the field case.

Partially connect the lower half of the handle assembly to the field case.

Tuck the wires into the designated slots and channels on the assembly.

Connect the lower half of the handle to the field case (manipulate the two components until they “snap” into place).

  7. Reinstall the lock-on button.

One side of the lock-on button contains a small tab. This tab should be installed facing the armature.

Install the lock-on button into the handle.

  8. Reinstall the paddle assembly.

Install the paddle assembly into the handle; ensure that the “tail” is positioned above the switch button, and the “fulcrum” is seated within the recess in the handle.

  9. Reinstall the top half of the handle assembly.

Partially install the top half of the handle assembly.

Align the posts (on the fulcrum and the lock-on button) with the recesses in the top of the handle.

Before securing the handle with the screws, test the paddle and the lock-on button for proper functionality.

Secure the handle with the screws.

You can't place a value on a job well done, unless you did it yourself. (Which you did.) Now you can place that value back into your own pocket. (Or into your business.) Not only did you refine your grinder at a fraction of the cost of replacement; you have expanded your skills far beyond the daily grind.

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