Always check cord and brushes first. in 5 of the last tools I repaired brushes were needed. The cord was broken at the strain relief. To replace the brushes I removed the motor housing, which exposed the brushes. Pull the springs back and rested them on the brush holder. Disconnected the old brushes and installed the new ones. For the c
... Read moreord. I removed the handle then unscrewed the cord clamp.Removed the cord leads from the switch, removed the cord relief, slid the cord relief on the new cord, then connected the cord leads to the switch.
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Brushes worn badly and screws missing from vibration
To get at the brushes on a Bosch chipping gun, remove the screws that hold the trigger handle (two are under the switch plate just pop it off with a screwdriver) slid out the brush covers, using a dental tool pull the spring up away from the brush and pull the brush out, replace with new brush, pull off the wire connector and replace with
... Read more new. slide covers back in and put handle cover back on. Pop the switch plate back on, may have to move it back and forth a little to get back in position.
Pulled off cover that mounted the armature of the motor. Pulled the removable electrical clips off of that assembly. Massaged the part that holds the brushes to clear the armature and the housing. I did not separate them which would have required a puller. I was able to carefully replace each of the brushes with the new ones. Reassembled
... Read morewith gear grease on the gears on the other end of the motor. Tested, and it is back in service with the service light extinguished.
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