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Author Topic: Replacing Brushes on the Run-on Pump  (Read 2060 times)

Offline martinrichard

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  • Model: Sharan Mk1
  • Spec: 2002 115hp
  • First Name: Martin
  • Region: South East
  • Country: United Kingdom
Replacing Brushes on the Run-on Pump
« on: December 29, 2016, 10:03:23 PM »
Replacing the brushes on the run-on pump

I found SilverBeasts post immensely useful and reassuring when doing this job:

https://www.fordmpv.com/smf2/ford-galaxy-reference-library/galaxy-replacing-the-run-on-pump-brushes-(tdi-and-v6)/#sthash.toDFl1PJ.dpbs

I had an interesting time replacing the brushes (with modified ones) in the run-on pump.
I found using cotton to hold the springs back almost impossible with the springs closing the brushes before I could get the commutator body inserted.
A friend advised that:
1) I set the gap with a matchstick
2) soak the brushes in water
3) freeze it all
4) remove the matchstick
5) insert the commutator body into the gap between the frozen static brushes.

It worked a treat.

I wasn't sure how to comment on SilverBeast's post directly but thought that this might add a little bit more to help someone do the job.

Brilliant Forum!

Offline Mirez

  • Pondering the next mod...
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  • Model: Galaxy Mk2
  • Spec: 03 115PS Ghia
  • First Name: Mark
  • Region: South West
  • Country: United Kingdom
Re: Replacing Brushes on the Run-on Pump
« Reply #1 on: December 29, 2016, 10:14:12 PM »
Good work thanks - Added to his post :)
03 Ford Galaxy 1.9 TDI 115 Ghia in Spruce Green Metallic
With cream leather interior, Full Bodykit, Remapped at 145bhp, Lowered on 18's
14 VW Tiguan 2.0 TDI 177 AWD R-Line in Deep Black Pearl
With panoramic sunroof, bi-xenon headlights remapped at 205bhp.
08 Ford Transit 2.2 TDI 115 in Frozen White
With retrofitted everything except another slidey door! :)

VCDS HEX/CAN - Scans/Coding done in Wiltshire in exchange for winegums! :)

Offline SilverBeast

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  • Spec: '05 TDI (130) Ghia
  • Region: Yorkshire
Re: Replacing Brushes on the Run-on Pump
« Reply #2 on: December 31, 2016, 10:06:20 PM »
I agree cotton was a right pain. Probably wouldn't use it again. Others have drilled a couple of holes through the plastic end cab and used wire/matches to hold back brushes. I guess a pin or picture frame nail would do probably be best as they would be stiff and unlikely to break off inside the motor.

Offline gregers

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Re: Replacing Brushes on the Run-on Pump
« Reply #3 on: January 01, 2017, 08:41:47 PM »
iirc i used a 3mm drill bit to hold them back.
vw t5 camper van.
reality is for people with no imagination
rip dad 21/12/10
rip mum 3/5/16
rip bruv 11/5/17
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