How to Replace the Motor Brushes on a DeWALT Router

Your router's motor uses two carbon brushes to conduct electricity to the armature. The brushes contact the commutator on the armature. The carbon brushes will wear down over time, from rubbing against the rotating commutator, and will need to be replaced. Worn brushes can cause excessive sparks around the commutator.

Let's get started.

REMOVING THE MOTOR BRUSHES   1. Remove the cord.

a. Unscrew the quick-connect collar on the power cord.

b. Disconnect the cord from the router.

  2. Remove the end cap.

a. Remove the four screws securing the end cap to the motor.

b. Lift the end cap away from the motor.

  3. Remove the motor brushes.

a. Use a pick to lift the brush springs away from the backs of the motor brushes.

b. Use long-nosed pliers to disconnect the wire lead connectors from the terminals on the brush ring.

c. Remove the motor brushes from the brush holders.

INSTALLING THE NEW MOTOR BRUSHES

  4. Install the motor brushes.

a. Install the new motor brushes into the brush holders. Note that the wire lead is offset to one side of each motor brush. The offset portion (where the wire attaches to the brush) should face down (allowing the brush spring to seat properly against the back of the brush).

b. Use a pick to reposition the brush springs against the backs of the new motor brushes.

c. Use long-nosed pliers to connect the brush lead connectors to the terminals on the brush ring.

REASSEMBLING THE UNIT

  5. Reinstall the end cap.

a. Install the end cap.

b. Secure the end cap with the four screws.

  6. Reinstall the power cord.

a. Connect the power cord to the router.