How to Replace the Carbon Brushes on a DeWALT Drill

Your drill's motor uses two carbon brushes to conduct electricity to the armature. The brushes do this through the armature's commutator. The carbon brush 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. The sparks can also be caused by a damaged armature, so you'll want to carefully inspect both components if sparks are present.

Let's get started.

REMOVING THE CARBON BRUSHES   1. Remove the end cap.

a. Remove the (4) screws securing the end cap to the motor housing.

b. Remove the end cap.

  2. Remove the carbon brushes.

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

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

c. Remove the carbon brush from the brush holder.

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

INSTALLING THE NEW CARBON BRUSHES

  3. Install the carbon brushes.

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

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

c. Reposition the brush spring onto the back of the new carbon brush.

d. Reconnect the brush lead to the wire terminal.

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

REASSEMBLING THE UNIT

  4. Reinstall the end cap.

a. Install the end cap.

b. Secure the end cap with the (4) screws.