How Do I Change the Brushes on a Porter Cable 7538 Plunge Router?

The Porter-Cable model 7538 plunge router is a large 3-1/4 horsepower router with a plunge base. This router's motor has a sealed-bearing armature that is vertically oriented in the motor housing. On each side of the motor's armature near the top of the housing is a small sleeve that holds a pair of motor brushes. If the motor stops running, you may need to change the brushes on a Porter-Cable 7538 plunge router, which can be done in a few minutes with some simple hand tools.

New Porter-Cable brushes
Flathead screwdriver
Metal pick

Instructions

- 1
  Disconnect the electrical cord from the power outlet.
- 2
  Remove any bit in the collet, and stand the router on its base.
- 3
  Loosen and remove the screws from the top of the motor housing cap. Lift the cap off of the motor, and set aside.
- 4
  Remove the caps that cover the brush sleeves on each side of the armature by prying on the caps with a flathead screwdriver.
- 5
  Slip a thin metal pick into one of the brush sleeves, and pull out the brush. Disconnect the lead wire on the brush from the spade connector, and set the damaged brush aside.
- 6
  Connect the lead wire from a new brush onto the spade, and insert the brush into the sleeve. Replace the brush cap over the sleeve.
- 7
  Repeat steps 6-7 with the brush on the opposite side of the motor.
- 8
  Replace the cap over the housing, and secure it by tightening the screws into the housing.
- 9
  Reconnect the electrical cord to the power outlet, and test the motor.

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