Big Car Club - MPV and SUV Forums

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!

Good work thanks - Added to his post :)

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.

iirc i used a 3mm drill bit to hold them back.