How to Replace the Carbon Motor Brushes on a DeWALT Sheet Sander

The sander's motor uses two carbon brushes to conduct electricity to the armature. The brushes make contact with the commutator on the armature. The brushes will wear down (over time) from rubbing against the rotating commutator. Worn brushes can cause excessive sparks. Sparking can also be caused by a damaged armature, so it is important to inspect the armature (around the commutator) as well as the carbon brushes.

Let's get started.

REMOVING THE CARBON BRUSHES

   1. Remove the cap.

a. Unplug the sander.

b. Remove the screws securing the cap to the motor housing.

c. Remove the cap.

  2. Remove the motor brushes.

a. Use long-nosed pliers to disconnect the wire lead from the brush holder.

b. Use long-nosed pliers to pull the brush spring away from the carbon brush.

c. Remove the motor brush from the brush holder.

d. Repeat this step to remove the second motor brush.

INSTALLING THE NEW CARBON BRUSHES

  3. Install the motor brushes.

a. Use long-nosed pliers to pull the brush spring back (out of the travel path of the motor brush).

b. Install the new motor brush into the brush holder.

c. Position the brush spring back onto the motor brush.

d. Connect the wire lead to the brush holder.

e. Repeat this step to install the second motor brush.

REASSEMBLING THE UNIT

  4. Reinstall the cap.

a. Install the top cap.

b. Secure the top cap with the screws.