Thread the new brush wires into the holes drilled previously, and set them so they will not overextend and pop out. Keep in mind the twisted wire might stretch a little during installation and make one of the brushes pop out slightly (like mine did). Leave at least 1/8" of the brush in the holder so it is well supported as it wears and so it has no chance of popping out over the edge of the holder. If you do a decent drill job, you can reuse the crimp sleeve to crimp and hold the wire, then solder each wire carefully. Don't use too much solder. If you lack soldering confidence, this job may be best left to someone else, or just buy a new regulator. You might have to use a clamp or some novel way of holding the wire while soldering, depending on how the crimp sleeves are looking after drilling. If the drilled hole is too big, fill in the gap between the hole and wire by inserting some extra wire, to help keep the solder from draining down the hole. Once the wires are soldered, clip off the excess.





Reinstalling the regulator can be tricky. It is easiest to do it with the alternator sitting on the workbench, but I did it with the alternator still on the car. I ended up unplugging the plug on the alternator for a better view. I also had to find a way to keep the brushes held in while trying to line up the screw holes. I pushed the brushes in, then wrapped a long twist tie around it to hold them. Then I screwed the regulator on partially and carefully removed the twist tie, releasing the brushes to extend and contact the slip rings. Then I did some final tightening of the screws and reconnected the connector for a voltage test.
The battery voltage went from 12.45 off, to 13.8 volts engine running. It works, yay. Eventually I would like to upgrade the voltage regulator to gain more charging voltage like others have done with these Bosch alternators. There are adjustable regulators and regulators with a higher voltage setpoint that will charge about 14.2-14.5 volts under most conditions. Many feel that 13.8 is too low for optimal charging performance, and I agree. But I have not had any dead battery problems when the alternator is working in daily use. And this is a stock vehicle, so the $2.12 brushes work for now.

Parts needed:
New aftermarket brushes were purchased at a local Alternator shop: Northwest Starter & Alternator, 7106 Eckhert Road, San Antonio, TX (210)-521-0011
I also found that Bosch brush sets can be purchased from most online Euro parts dealers, use part number 1 127 014 011 (cross references to F4121-36736)

These usually sell for $5-7 plus shipping. They appear to come pre-shaped to the slip ring's arc, whereas mine were arced differently, as if to be used in a different application. The guy just matched them based on size, so they must be some universal rebuild parts. I made no attempt to try to reshape mine, but some people try to match the arc to establish good contact right away. Mine seems to be charging fine, hopefully it will last another 150,000 or so miles. The old ones lasted somewhere beyond 115,000 because the odometer was inop when the car was purchased.
Beware that a worn slip ring surface can consume brushes at an unacceptable rate. So make sure to take a mirror and flashlight and check for any anomalies, verify that the slip rings have a smooth surface. Some people recommend deglazing the surface with some fine garnet sandpaper. I didn't do this.

Good luck, I hope this helps somebody.
:fork_off: