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There are 2 10mm bolts on the bracket that need to be removed. I'm pretty sure that allowed enough movement in the bracket to let you remove/refit the blower motor. You don't need to take the full bracket out. I had the same problem with mine a couple of years ago. Fitted new brishes from ebay...

If the brushes are worn down to approx 10mm in length then thats when they'll start to cause problems. new brushes are 22mm long

I had similar problems. I stuck a set of these brushes in and its been fine for over 2 years now. I'd rather pay £12.50 for the correct brushes and fit them in the OE motor than opt for some cheap crap motor thats probably made for 20p in China...

Blower motor brushes are common faults on A4's and Passats. Replacements are on ebay for £12.50 http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=190349589225&ssPageName=STRK:MESOX:IT

What replacement brushes did you use? If you use these ones then they should be fine. I used these in my Passat and they're perfect - as good as OEM. (There's a way you can fit them without needing a soldering iron but you need to cut a wee bit off the end of the brush)...

What temperature sensor did you replace? My 2000 Passat Tdi has started to run sluggish tonight (according to the missus) and i'm trying to find what could be wrong. The Air Mass Meter was changed about 2 years ago. I'm hoping it is the air mass meter again as i may get it changed under parts...

New brushes are available for these heater motors. I have recently fitted a set of these brushes to my Passat and they worked a treat. £15 and its sorted http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&ssPageName=STRK:MESELX:IT&item=190259813033

I appreciate that this is an old thread but for anyone who's having similar problems with their A4 heater motor new brushes are available on ebay. I fitted a set of these to my Passat and they worked a treat...