Your description tells me why you replaced the brushes. It started sputtering, going intermittent. Some brushes are made with short springs to cause that to happen. others have a slot down the side that ends near the spring. There is a tab in the housing that latches on to the end of that slot when it gets too short and stops the brush from being pushed any farther.
The Dahlgren motors used the slot system and saved many motors. Of course the RF snubbing system in the motor burned out the commutator really fast, duh.
Philadelphia, PA (Really Bensalem)
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