Dyson DC25 Stripdown and Refurb

[beko1987]

• Tweet

Thought I'd post this up here incase it is of any interest. Got a DC24, 25 and 04 recently for free, bloke's missus had killed them all and he wanted them out of the garage.

With this being the newest dyson I have worked on, I took lots of pictures of the process, to hopefully aid me when putting it back together!

But, if any of the pictures help out then great! This machine runs and the brushroll spins. It needs a new wand, a few spring buttons, a brushroll and filters but I;m waiting until its back together and working well before shelling out for that.

So...



Hose off



Cyclone off



and brushroll off







Cover off



Switch for refrence on re-assembly



round hose off



One side of the ball is unscrewed



and the other side, being careful not to rip the wires out











Refrence shots of the wiring. Once all unplugged...



Cable holder and pivot removed now



The yolk was then popped off the end supports



Lots of lovely wear starting on the ball



motor filter out



And the outer ball removed



Whatever this small piece of plastic which has been merrily shedding itself is removed



Large ball race removed. Span well enough but felt a bit dry so will give it a lick of grease before putting it back



Motor seal removed



4 more screws and the motor can come out



refrence shot of how the wires go through the outer casing





Rubber holder removed



Motor removed and unplugged...hang on, whats this...







Left no traces so assuming everything will be ok!





Made a start removing the wheels and red pedal

Refrence shot of the spring





Another spring





and the red pedal snapped out of the wheels



Another spring that looks fiddly to put back on...





Not sure what this does, but it looks worn





Just the wiring left now



Part of the carriage assembly removed



and the rest off



Flap off



Undo the screw and flick the black axle thing out



Stripped



Looking a bit bare now



Switch cover off next



Not a *ping* moment thankfully



Wire city





Trunk wire can be removed now



removed the cyclone clip











One stripped chassis



Screws so far



Yolk next



Wire cover removed





Removed the wires by flicking the tabs up to release them





Floaty bit removed





Done. Chunky bit of plastic this bit!





Brushroll next



Peaky looking brushroll removed



I hear the end caps are prone to killing themselves. The brushroll was very rattly, does this look ok to anyone who knows?



The usual...





Snapped a bit off the end removing the insert. Should be ok for testing purposes though





Corner wheel off



With the only cross headed screw of the entire project





Had to remove the belt to split the assembly



Cog removed



and bearing tapped out. Will re-grease this before re-assembly









Down to the motor now









All electronics removed



After a good clean with contact cleaner





Had to glue the little bit of plastic back that snapped off to reveal this, inevitable though and well hidden.





More wires removed



I think I've saved this motor from inevitable death



Not really needed but could clean up the oily dust that had accumulated



And finally the bumper off



Yummy



Proves that clear plastic on a vacuum looks good for about half an hour, then just looks crap!

Cyclone next



Top off



Top stripped



Cyclone flap release button off



Naked top



Filter out, dont think its ever been washed. The DC24 I got from the same person was completely clogged, had to vac it off before thinking of switching it on, compared to that this is squeaky clean...



Clear bin split. Sadly its been blasted over time and is no longer shiny (earlier cyclone bins werent this bad, I;ve had DC01 bins still good as new...)



Not much to go now









Snapped off the bottom part and scraped the accumulated crud out







and the final seal is removed



Pile of washing



Pile of small bits to be done by hand/just wiped over (not full on washed)



Non washable bits



Wasnt too filthy tbh, worked on worse (have had DC14's I've had to vacuum 4 or 5 times throughout the stripdown)



Every screw for a DC25



Seals were then cleaned





























Everything washed with high pressure hot water, some kitchen cleaner and a good scrub with a nice stiff paintbrush, I started assembling in reverse order, and got cracking with the cyclone











Couldnt get that bit of dirt off short of sandpaper 







Washed the filter out for now, will buy new if I feel it deserves it!











Side by side with my DC24 Cyclone (the 25 is a test run for stripping and refurbing the much smaller and fiddly looking 24...)

And that's it for now! Have started re-assembling the brushroll, but spent half an hour last night working out what goes where, so hopefully should progress once my lovely daughter goes to bed tonight!

[Angus Black]

Great set of photos and info. The site needs more of this. 

[beko1987]

Thanks! I had noticed a lack of proper teardown threads, and since I was stripping it down anyway thought I should post my findings!

She is back together now. Not as many pictures, mainly because I was scrolling back through them on my phone to work out what goes where, but it wasn't too bad, just fiddly, and trying parts in 2 or 3 different orders until it made sense and went back together.



Motor and wiring back into the floorhead. Put a few drops of oil on the motor bearings in the hope it soaks in and prolongs its life a bit!



Annoyingly the bearing housing end of the brushroll baseplate had cracked. A bit of glue capillaried into the cracks seems to have sorted it.



Belt back on



And all done.





Screws decreasing slowly



Pictures get even more sporadic, so if your following this thread in search of repair info, assembly is as Mr. Haynes always says, just work from the bottom of my first post up!



The power wires threaded through the yolk

I've seen this asked before on here, so here is a picture of how the brushroll switch fits together



Switch housing back together



Pedals and wheels back on



All the wires replaced back in the cable tray correctly. I then dropped the ball whilst manouvering it and pulled them all back out so make sure its all well supported when doing this, not resting on your getting-dead leg...



And back together!



No idea if it works or not yet, was half 11 when I finished last nigth, and my daughter would have woken up as soon as I turned it on, then the missus would have woken up as well and that's not a good move!

Providing it all works as it should, I can get on with buying the bits it needs:

Wand assembly
New Brushroll
New Filters
Wand end cap
The button and spring that fits onto the end of the hose to clip into the wand/onto the tools

Will test drive it later when I get home from work and see if I've improved it, or if it's still fit for the scrap pile!

[MVacs]

Our eBay listing for brushrolls is currently the cheapest out there. Only because we got some in a deal.

[beko1987]

What a coincidence, I've been watching that one! Just bought it too, along with a wand and end cap, and brushroll. New filters makethe total spend quite high, so will leave that for now until I get paid.

The good news is she's good as new! Just run it round the flat and the suction us restored, it's smooth in its operation and it all works!

The Brushroll is fine in use, no odd noises but I will replace anyway as the locating mouldings are worn down and some bristles are missing. It's also annoying to use atm as the wand doesn't secure down.

Got a quick video uploading to YouTube, will post it up when finished!

[beko1987]

The wand turned up today, so I swapped them round, and then took the broken one apart.

Broken one is on the bottom



The new one worked, but was a bit tough to work. Decided to strip the old one apart and see how it works

Flick the 3 metal tabs out



The plastic end comes out



Bend the tabs back flush, and the pipe withdraws from the top of the wand



Push the two plastic tabs in, and pop/pull the grey bit of plastic out. The clear piece of plastic sits inbetween the grey bit with tabs and the handle housing, and un-locks the wand from the cleaner (this was what was broken on it)



The half piece of clear plastic sits inside the plastic shown. Not sure what role it plays



This is whats left. It locates the metal pole and keeps everything straight. I removed the screw but couldnt get it out, so left it



This little chappie sits right at the top. When you pull the red end of the pole up to extend it, it unclips this on the way



The two trim bits come off as well



The 'new' assembly was in worse condition than the old





I then put the whole thing back together. Didn't really do anything special, but once back together, I thought I should try it on the cleaner one last time...

and it clicked down and locked on correctly

and the pole extended and retracted smoothly and more easily than the new assembly...

Basically I had fixed it. So I swapped the end cap onto the old handle, and left it on! Now got a spare handle which I will probably take apart, put back together and see if it improves and either put it in the garage as a spare or back onto ebay with it!



http://youtu.be/Is1KN4aSCls

[beko1987]

Thanks to the good service of ManchesterVacs, I was able to complete the DC25 just now (come home from work feeling rotten but couldnt resist fitting the parts...)



It's either been abused or the brushrolls aren't what they used to be...



Looks much smarter now



And the finished machine (and the sale pictures...)









So, there you go (if anyones still reading this). Newer Dysons are strippable, but it's alot harder work than the older ones. The 25 works well now, grooms the carpet better than it did (not a patch on a Hoover Turbopower though...), has very strong suction, a nice handle arrangement and looks the part too. And to think, it was being taken to the tip if I didn't have them, and now it's good as new, apart from the obvious cosmetics of a used vac.

I hope these pictures help anyone else looking to troubleshoot a repair on their DC25.

Now, I must get round to the DC24 and DC16 that need doing... (and an early DC04 Absolute+, but I think that is too far gone to be worth it)

[stpopken]

Thanks for posting the complete stripdown. I will probably need it when I put my Dyson DC25 back together. The motor on mine quit working, so when I took it apart 7 pennys fell out of the motor. Those pennys ripped some of the fan apart and torn away some of the plastic. Would anyone know how a bunch of pennys would have gotten sucked into the motor? Also the cleaner head does not turn. I put the cleaner head on my working DC25 and still does not work. Other than the cleaner motor being bad, any other ideas. Here is a picture of the motor and what the pennys did to it.

[beko1987]

Oof that's a lot of damage! There must be a design flaw somewhere to allow such bits into the motor! Impressive though, and a novel way of turning 6p into 40 notes!

Does the pcb on the head look burnt? Since you have tried it on a machine you know work it sounds a bit suspect, does your working head work on both machines?

[stpopken]

No nothing looked burnt. When i cleaned out the clear head, there was some black dirt, which could have been caused by someting burning. And yes the working head did good on both before i took the bad one apart. Could the bad ball motor cause the cleaner head go bad. The reason i ask is when i put the good cleaner head on the bad machine, it seemed to want to hesitate on/off like it was ready to stop.

[beko1987]

The two motors are seperate, I had a dc24 with a broken motor and the Brushroll was fine. Check the wiring to the head, and check the little switch that sits under the side cover, this turns it on and off as the cleaner stands and reclines. There's also a little microswitch under the main switches, check that too.

Just unplugging and replugging everything may kick it into life.

Is it possible the black powder could be the remains of the carbon brushes in the Brushroll motor? If so then  cleaner head

[stpopken]

Thanks, I will take a closer look this weekend. Taking a nap as I have to work tonight. I will then let you know how it turns out.

[beko1987]

Don't blame you. The missus has just gone to do a night shift. I'm getting my daughter to bed then cracking on with jobs!

[beko1987]

Well, after an ad on Gumtree came through, the DC25 sold to a nice lady who has swapped their 1 bed flat for a 3 bed house due to an impending baby, and their DC26 just can't cope.

She got a bargain at £80 for the machine, and is very happy. I advised her to turn the brushroll off for hard floors to prevent it going bang as they do, and showed her how to wash the filters!

Have learnt alot about DC25's. In future (unless they are free, not fussed then) I will ensure that the wand fully works, as well as both motors. Everything else is just a case of remove, strip, clean and re-assemble.

And I can tick a DC25 off my 'machines I have not owned' list.

[birdog9999]

Beko1987

I have a Dyson DC25 animal almost from the beginning I have not be able to get the wand to separate from the body. The wand pulls up almost of the way but will not release the handle from the body. I have followed Dyson's video but the hose is not twisted. I have tried everything to get the handle separated from the body but I can't figure out what is holding it together. Since I can't get the handle free from the body I can't take it apart to see what is locking it together. In your pictures you show a clear plastic part that you say locks it. Do you have any idea how to get the handle apart from the body so that I can take it apart to see what is broken?