How to Replace the Brushes on a DeWalt

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Carbon electric brushes conduct electricity between a tool motor’s fixed wiring and its moving parts. The nature of the components is that as they brush against the moving parts, they wear out, and brush wear is one of the most common causes of tool failure. Many of DeWalt’s power tools include replaceable brushes, including the DeWalt saws. You can usually tell that brushes can be replaced on a tool because the motor will be easily accessible with an end cap.

Things You'll Need

  • DeWalt brushes
  • Unplug the Dewalt tool from the power supply and identify the end cap on the motor. On a miter saw, for example, it’s at the back of the motor housing which is between the blade assembly and the pivot. If in doubt, the motor housing is usually where the wiring goes to, and the end cap is always on the motor housing.

  • Unscrew the end cap by unscrewing the retaining screws with a screwdriver. Then lift the brush spring and take out the brush assembly. You can identify the brush assembly because it will include the carbon elements adjacent to the motor. The carbon part of the brushes will be curved towards the motor.

  • Replace the brush if it’s visibly worn. On a miter saw, wear down to about ½ inch remaining requires replacement because the spring won’t exert pressure anymore. Identify the markings on the brush and replace the brush with an identical part by orienting it in the holder the same way it was before you removed it.

  • Replace the motor end cap, plug the saw in, and run the motor for about 10 minutes before starting any work. This will seat the brushes and allow the electric brake to settle before work.

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