Hello Dan,

Pulling the brushes by removal of the voltage regulator assembly looks easy but can be difficult if the two screws are corroded in place.

I'd spray a little PBlaster on those devils. I've also found it more advantageous to remove the two screws with a pair of needlenose vise grips rather than a stubby phillips or flat blade screwdriver.

If you elect to remove the alternator for this procedure, the job becomes a bit more involved but the screws are a little easier to deal with.

Lastly, in all likelihood, as the other posters have indicated, your brushes are the culprit. If the brushes do appear to be quite worn (I believe there's a picture and measurement in the Bentley) I'd replace the entire voltage regulator and use the other as a spare. With that one, you can replace just the brushes and you'll then have a good spare for your next 240.

Good luck,

Marty Wolfson