Carbon Brush

I found your video on you tube on how to replace this brush. Thank you, it made it easy. Here is a copy from you tube of the video for those of you that need it.

https://www.youtube.com/watch?v=kLSOOKZxpyI

When the brushes went out on my angle grinder it was sudden, there wasn't any shuddering or anything like that. I thought it might have been the switch but what I realized when I opened it and looked at the brushes is that the brush itself has a spring loaded button inside it. When it get to low the little button pops out and stops the tool. I thought it was quite clever although it may be why they cost a bit more than most others. Its pretty basic to unscrew and open the case on the grinder and locate the first brush. The tension arm is red and has a spring to hold it down. Carefully pull the spring back with pliers and then pull the brush out. the one on the other side is a bit trickier to get at though. You'll have to gently pull the whole apparatus away from the case. This back case holds an armature that activates the switch which is in the back of the tool. try not to jumble things to much and make sure that you keep in mind how things go back together. I would suggest that if you find a bad brush on the first side like I did then just order new ones before you take everything apart, by the time you get them in the mail your memory may be a bit foggy on the reassemble procedure. I couldn't get the switch to line up at first but then I realized that the whole case was turned 90 degrees the wrong way. Once I figured this out the hardest thing was getting the wires to line up where they were. If the case doesn't want to fit perfectly back at first then just keep gently pinching it back and forth for a little while, the internal parts fit very tight in the case. So far the tool is working fine for me.

Dewalt 7amp grinder
Remove (4) torx screws, disassemble cable holder which gives you access to brushes
Simply pull back spring that holds down brushes and pull off connector pin and reverse procedure

1. Opened up the grinder case
2. Removed the old brushes.
3. Installed the new brushes.
4. Put the grinder back together.

Unscrewed outer case ( screw driver).
Removed outer case. Located brushes. Used a needle noes pliers to unplug wires to brushes (2) brushes. Used small flat tip screw driver to pop the clip holding the plastic brush housing in place. Remove old worn brushes, and replaced with new ones.
Then reversed the procedure reassembling the grinder.

Removed rear halves of grinder exposing brush holders. With a small screwdriver, lifted brush tension spring and replaced worn brush with the new one replacing tension spring. Repeated this process on the other side and carefully replaced halves in the original position.

Removed the case
Disassembled the armature assembly
Removed and replaced the brush spring, arm and carbon brush
Reassembled the armature
Reassembled the case
Inspected and tested the unit

Finished replacing springs and brushes.

Replaced the carbon brushes.

Remove the side cover, replace the brushes, replace the side cover.