did you clean the comutator before fitting the new brushes, try taking off brushes and with a brillo pad, clean the bronze colored segments where the brushes sit, when you re fit the brushes, make sure they are on properly, other wise the motor will click like hell when you fit them back.
also before you fit the brushes, place your finger on the bronze segments and turn the shaft very slowly, if it feels like one of the segments is out of place, change the motor.
richard, June 2004