Range Rover Air Compressor Thermal Switch Installation Instructions
Last Updated: 08/31/2010
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If you have any questions about this procedure, don't hesitate to ask. You can email Rover Renovations help or call 718-249-5557 for clarification.
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 | The Thermal Switch resides in the brush housing assembly, at the end of the motor. Remove the mount bracket and the 2 long bolts. Gently pry up the motor end, pry the wires out as well.
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 | Use a 7/64 drill in a drill press (DO NOT USE A HAND DRILL!!!) to drill out the rivets, go appx 1/4" deep. This hole will be for the new mounting screws (included with the thermal switch kit.) Gently pry the brush-plate off with a screwdriver and clean up the burrs with a razor knife |
| New Cell | Use a 1/8 drill to drill out the thermal switch rivet |
| New Cell | De-solder the old switch and replace with the new. It's easier to rivet (also included with the kit) the new switch in before soldering. |
 | Discard the plastic ring, it's only purpose is to create bearing failure. It is loose in 90% of the compressors we see, if it's still there, pry it out. Re-assemble the bearing if necessary and oil with a few drops of light machine oil. |
 | Press the bearing retainer down with a flat blade screwdriver and re-crimp with the side of the blade and a hammer. Use a solid surface with a hole for the dimple so the end bell will sit flat. The base of your drill-press will work very well. |
 | New Cell |
 | Clean the burrs from the end bell, screw the socket head screws into the holes drilled previously, they will cut their own threads. Start with your electric driver on low torque and slowly increase until just seated, or run in by hand.
Ensure the brush assembly is fully seated on the end-bell, misalignment will cause brush chatter and vibration. |
 | Hook the brush spring on the end of the guide, it's tricky...
Install the brushes in the quides with the leads along the spring slot to allow free movement. The black wire goes beside the post for the orange wire connection (overheat switch lead). |
| Clean all the old brush dust out of the motor, a damp cloth works well. |
| New Cell | Install the end-bell, wires facing the valve block as the compressor sits in the EAS box.
It's tricky to get the brushes over the commutator, use a small screwdriver to hold them back if needed, un-clip the springs and ensure the brushes seat correctly. Re-install the bolts tight enough that there is no rotation of the motor housing. |
 | Test the thermal switch, if it's open odds are the orange wire connection came loose when you re-installed the end-bell. |
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| New Cell | New Cell |
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| New Cell | New Cell |
