Question about Milwaukee Tool Milwaukee 1/4 Sheet Orbital Palm Sander - 6016 - 6

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Cannot disassemble Milwaukee 6016 to replace brushes

I have removed the screws and partially separated the body. After it separates about 1/4 inch there is a catch that prevents complete separation. The catch seems to be somewhere in the lower part of the body. What is the trick/technique to get it open?
Thanks, Giles

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Exactly what screws did you remove. you have to remove the bottom platen first (pad) then remove the housing screws. you need to remove the fan also and then might need to apply some pressure to split the housing halves.

Posted on Mar 03, 2009

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Disassemble


I am guessing this is the same one that has the clogging issue. Normally the screws for dismantling are in recessed holes ( they are a few inches deep) and fastened with Phillips head. You will be able to see them with a flashlight. Take off the bag container door and remove the bag or dirt collection bin. There will be screws behind that as well. On the bottom there will be screws that hold a cover over the beater brush. when that is removed you should see the belt and the slots that the beater brush seats into. That just pulls out. Once inside there are separate screws holding the 90 degree turns for the hose path. Prob 2 of these. Make sure you go through the ENTIRE hose path. I guarantee there is a big clog of hair, paper, pencils and small animals in there. If not confident in remembering how to put back together take pictures.

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Your alternator-mounted voltage regulator has failed. Luckily, your voltage regulator is
replaceable separately from the alternator (most voltage regulators are integral to the alternator,
and cannot be separately serviced).

Note: this works for 3.8L cobra alternators/voltage regulators only - in the 4.6L model, the
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1999 Ford Mustang Cobra -3.8L engine

3.8L Engines

1. Disconnect the negative battery cable.

2. Remove 4 Torx® head screws holding the voltage regulator to the alternator rear housing. Remove the regulator, with the brush and terminal holder attached.

Fig. 1. The regulator and brush/terminal holder are mounted on the backside of the alternator

archaeology_70.jpg


Fig. 2. The regulator and brush/terminal holder are secured by 4 Torx® head machine screws


archaeology_71.jpg

Fig. 3. Hold the regulator while removing the screws to prevent the regulator from dropping out and damaging the brushes

archaeology_72.jpg



3. Hold the regulator in one hand and pry off the cap covering the A terminal screw head with a small prybar.

4. Remove 2 Torx® head screws retaining the regulator to the brush holder. Separate the regulator from the brush holder.



Fig. 4. Slide the regulator out-the brushes will move out of the holder

archaeology_73.jpg


Fig. 5. The brush and terminal holder can be separated from the regulator once it is removed from the alternator

archaeology_74.jpg


=========================================================
To install:

1. Install the brush holder on the regulator with 2 retaining screws. Tighten the screws to 25-35 inch lbs. (2.8-4.0 Nm).

2. Install the cap on the head of the A terminal screw.

3. Depress the brushes into the holder and hold the brushes in position by inserting a standard size paper clip, or equivalent tool, through both the location hole in the regulator and through the holes in the brushes.

Fig. 6. When installing the regulator, press the brushes back into the housing

archaeology_75.jpg


Fig. 7. Use a thin piece of soft material, like this plastic wire tie, to hold the brushes in position while replacing the regulator, or use a paper clip inserted in the hole

archaeology_76.jpg



4. Install the regulator/brush holder assembly and remove the paper clip. Install the attaching screws and tighten to 20-30 inch lbs. (2.3-3.4 Nm).

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