Sorry, I don't remember how the connector came out, but I don't recall any issues. I bought 2 pairs and still have to redo one, but the first motor I rebrushed is still going strong. I used a small chisel to stake the metal tabs and then a regular poly epoxy to seal it up. (one part liquid). I have noticed some variability of speed in the motor, but it may be due to the replacement solenoid system I put in ( an unwired tools one about 5 years ago).

Also, If I remember correctly I may have ground the end of the brush down a little because it seemed a little long and it contacted the commutator/stator? better that way. I think I ground at like a 45deg angle? Wish I had kept a photo record. As I remember the procedure went pretty smoothly and the dimensions of those K44's were spot on. How cool is it to be able to source stuff like this with a few simple keystrokes!

Just a quick tip from a newbie, if I may...

My blower motor recently went out on my '80 300SD, or at least it was on and off. I've heard others describe them coming on with a bump in the road or with a tap, and that's exactly what I found when I took out the glove compartment and tapped on it. It would make a little grinding noise and start right up almost every time.

I assumed I needed to replace the brushes, and wasn't looking forward to it cause I have very little expertise in soldering. Also, I didn't know how to get the back casing off. It had the factory epoxy (the yellow stuff in the above pics), and I razor scraped as much as I could away but I didn't know if I should try to heat up and melt the epoxy or what.

Well anyway, while I was working on that, I noticed a pile of black dust began to form, as others have described. But it was a lot. All coming out the side hole as I was turning it around and over, turning fan, turning it over again...so I kept doing that for a while, shaking it vigorously, and I ended up with a very nice pile of dust and debris. I took a picture, but unfortunately my phone deleted it.

I still could look in and see flaky carbon like dust, so I took a vacuum to it, and when I felt good about it tested it, it worked, and I reinstalled it. Has worked perfectly since, about a week.

Granted, it might be only a temporary fix, and I will probably still have to replace the brushes. But I thought I'd mention this to everyone as something to try first.

Thanks for all the help on here, this was an excellent thread.

Don't know if this will help, but I bought brushes for a different Bosch motor from these guys:

Back- And Side-Shunted Brushes

I just rebrushed mine. A couple of tips...

If you're careful removing the back plate it can be reinstalled without epoxy. The area of the "can" where the back plate mates has slightly angled sides where the back plate fits. It looks as if the back plate "tangs" have an arch (When looking from the side) and they expand when the parts are pressed together locking the back to the can. It's hard to tell with all the goop and when the back is just pried up it screws up the angle.

Looking at the side of the can the "slots" look like this /_______\

I had to re-file the angles and bend the "wings" on the back plate to get it together and pressing on the center of each "wing" (From the back of the motor) locked them in place.

Sorry, no pics. Hope it makes sense... Just look at it carefully before prying it apart.

I also used some mystery brushes which I filed down to fit. It works fine but it smells funny... WTF :confused: Could be the brushes, oil, etc.

Hopefully the smell will go away...

Some pics:

http://i711.photobucket.com/albums/w...SANY0034-2.jpg

http://i711.photobucket.com/albums/w...SANY0029-1.jpg

The brush assy:

http://i711.photobucket.com/albums/w...SANY0032-1.jpg