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Author Topic: Replacing Brushes on the Run-on Pump  (Read 2242 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:


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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  • First Name: Mark
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  • 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
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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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.
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