Drill out the top of the soldered connection of the old brushes because they are not only soldered, but crimped in place, then they shoot out of their sleeves. Make sure you don't lose the springs that are behind them with the small insulator sleeves on the brush wire. Then place the new brushes (along with the springs and teflon insulator) in the reg. assembly. Fold the wire over so that the brushes don't try to pop out while you're soldering, then try to crimp the hole the wire came through. Solder the wires, and trim the excess wire off (~ 1.5" - 2").
Alternator Rebuild
Bosch P/N 30091 is the brush/voltage regulator block, and should be available for ~$20. You can remove the brush/Vreg block w/o removing the alternator -- just disconnect the battery and remove the two slot head screws from the back of the alternator w/ a right angle blade screwdriver (wouldn't want to accidently short across the B+ termanal with the battery connected now, would we??). New spec. for the brushes is 10mm protruding from the plastic, (the longest edge) and min wear spec. is 5mm.
