Sorry to bump this old thread, but I've recently come across a motor with a similar problem. Instead of trying to repair the commutator, I've decided to try and fit a readily available motor. It's still a WIP and also doesn't work yet, but I thought I'd share it with you. LEGO 12V train motor repair (1) by alainneke, on Flickr The axle of the motor (Motraxx 265) is 56mm, or 4mm shorter than the original one. If this causes problems, I'll probably fix it with some plastic bushes on each end of the axle LEGO 12V train motor repair (3) by alainneke, on Flickr Here you can see the axle mounted using the original LEGO magnets and housing LEGO 12V train motor repair (4) by alainneke, on Flickr So far so good, but I still have to figure out: - how to remove the worm wheels from the old axle? - the correct position for the carbon brushes: the motor will not run with the brushes in their original position, but it does run when I push some wires against the commutator