How to Replace the Motor Brushes on a DeWALT Chop Saw

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

Let's get started.

REMOVING THE MOTOR BRUSHES

  1. Begin by removing the motor cap.
2. Remove the wire lead.
3. Pull the tension spring away from the brush.
4. Pull the old brush out of the holder.
5. Repeat on the other side.  

INSTALLING THE NEW MOTOR BRUSHES

  1. To install the new brush, insert it into the holder.
2. Place the tension spring on the rear of the brush.
3. Reinstall the wire lead.
4. Repeat the process on the other side.
5. Finish up by reinstalling the motor cap.