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Author Topic: Clutched Dyson DC04 - Motor Replacement Guide  (Read 986 times)

Online beko1987

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Clutched Dyson DC04 - Motor Replacement Guide
« on: April 03, 2017, 01:02:28 AM »
I took the pictures for this a while ago, and keep forgetting to write it up! Let's fix that now.

This is for a CLUTCHED DC04, the one with the knob on the side.

(Already removed in this picture)



Ingredients

1 new motor - https://manchestervacs.co.uk/Dyson/dyson-motor-ydk-yv-dc04-dc07-dc14-dc27-dc33
1 new post motor filter - Either a Hepa
https://manchestervacs.co.uk/Dyson/HEPA-filter-DC04-DC05-DC08-DC19
or a pad (both interchangeable)
https://manchestervacs.co.uk/Dyson/Dyson-Post-Motor-Filter-Pad
T15 torx driver - https://manchestervacs.co.uk/Dyson/Dyson-Torx-Star-Screwdriver-T15
DC04 Switch removal tool - https://manchestervacs.co.uk/Dyson/DC04-switch-removal-tool

So, on with the show!

First, take the cyclone unit off

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Drop the cable

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Remove the hose. You do this by pushing in and up on this locking tab under the cord hook, and the hose will lift up, then you pull it out.

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Remove the switch cover by inserting the removal tool into the flat side of the cap and gently pushing inwards, until it lifts slightly (there's a tab in there). Then lift it out.

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Undo the screw

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and lift the switch housing out

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You will see this. Be careful of the sticking-out bit, as they do snap (but it's not the end of the world if it does). You want to remove the wires that run into the machine

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Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Online beko1987

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Re: Clutched Dyson DC04 - Motor Replacement Guide
« Reply #1 on: April 03, 2017, 01:05:38 AM »
Like so

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Pop the cover off the live wire. The switch removal tool is good for this

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Using a screwdriver, pop the clutch cover off. Levering at the top and bottom usually does it

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Next, remove the post motor filter by levering up on the tab

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and remove the filter

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At the back of the machine, remove the U-Bend

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Remove the changeover valve

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Underneath now, and remove the baseplate

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Online beko1987

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Re: Clutched Dyson DC04 - Motor Replacement Guide
« Reply #2 on: April 03, 2017, 01:11:32 AM »
I'm fancy and have a belt lifter tool (https://manchestervacs.co.uk/Dyson/Dyson-Belt-Removal-Tool but if your belts are used and a bit stretched, you might be OK without it.

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Either way, remove the brushroll

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Pull the internal hose off from the machine

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Then very carefully remove the brushroll housing. I tilt it as far forward as it will go, and lever each end out with a screwdriver, which is a controversial way of doing it... Basically don't break the tabs



and remove the brushroll housing

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Next, remove the circlips holding the cleanerhead onto the machine. Find an end and lever it up with a screwdriver

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and they fall off

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Remove the clutch. One screw sits deep in the hole you can see at the top, the other two are easily seen

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The clutch cover lifts off then

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Once the cover is off, pop the motor belt off the spindle, then 'recline the vac', and pull the parts of the head that once housed the circlips out and lift the head off





Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

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Re: Clutched Dyson DC04 - Motor Replacement Guide
« Reply #3 on: April 03, 2017, 01:13:40 AM »
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With that done, remove all the screws

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Then pull the spinal cable out of the chassis, and lift off the motor housing

Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

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Re: Clutched Dyson DC04 - Motor Replacement Guide
« Reply #4 on: April 03, 2017, 01:17:04 AM »
Pull gently outwards on the motor housing cover and that pops off

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Pop the 4 tabs out that hold the retaining ring on

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Push the cable grommit into the housing

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Then you need to remove the motor. I do this by placing it on the floor belt spindle down, then pushing hard on the housing which pushes the motor up. Then just grab the big seal and pull!

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Yep, that's knackered! (If you are wondering why this machine is so clean, I'd refurbished it for sale, was testing it out and it blew... sodding thing!)

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You want the two rubber seals off the dead motor, one at the top

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and the large fancase seal

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Then take one new motor

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Re: Clutched Dyson DC04 - Motor Replacement Guide
« Reply #5 on: April 03, 2017, 01:21:09 AM »
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Refit the seals (the belt spindle one does not need any special orientation on a DC04)

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Feed the cable back through the motor housing a bit

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I smear a thin layer of grease around the inside of the motor housing to make this next part very easy! You then insert the motor, making sure the 2 pegs align with the holes on the rubber seal, make sure the cable grommit also starts to pass through the housing

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Then push it home, refit the retaining ring and pull the grommit fully through

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Pop the cover back on

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Fit the motor back to the main machine (a smear of grease on the suction pipe where it meets the fancase seal helps that too)

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Do up all the screws

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Feed the cable back through the chassis

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Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

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Re: Clutched Dyson DC04 - Motor Replacement Guide
« Reply #6 on: April 03, 2017, 01:24:07 AM »
Next, refit the cleanerhead and pop the belt back onto the motor

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Pop the circlips back on

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At this point, check the head pivots smoothly and fully, it should ride in this inner groove

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Offer up and push the internal hose back on

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Then clip the brushroll housing back on

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Lift the belt/refit the brushroll

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And pop the baseplate on

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Refit the U bend

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Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

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Re: Clutched Dyson DC04 - Motor Replacement Guide
« Reply #7 on: April 03, 2017, 01:28:04 AM »
Refit the changeover valve pipe

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Pop the new filter in and fit the filter housing (there's a notch at the front which aligns it)

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Fit the machine wires to the switch housing as so

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Use the kinks in the cable as a guide as they have to be the right length for the housing to lift up and slot in

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Push it home and screw it up, but don't fit the switch cap just yet

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Refit the hose and wand



And the cyclone



Now, test it! Check that it works and the motor wires have not pulled apart, check the brushroll operates, check everything moves and pivots properly and check the suction. If all is well, then fit the switch and clutch covers!

And done!

Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Offline Elgin

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Re: Clutched Dyson DC04 - Motor Replacement Guide
« Reply #8 on: April 03, 2017, 06:11:41 PM »
Remebering swapping the cable for a purple one with a yellow plug instead of a purple one with a green plug when me and my nan swapped cables, Broke both of the bloody button cable stalk thingys.
Also that motor looked exactly how my nans Absolute looked last week when I did the motor replacement, Black inside - my dad reckoned its supposed to be like that, im certain its supposed to be the golden colour - NOT black

Online beko1987

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Re: Clutched Dyson DC04 - Motor Replacement Guide
« Reply #9 on: April 03, 2017, 06:21:18 PM »
No it'll go black, that's the carbon brushes running against it. It'll take a few weeks but it'll go black and be fine.
Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Offline Elgin

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Re: Clutched Dyson DC04 - Motor Replacement Guide
« Reply #10 on: April 03, 2017, 06:28:07 PM »
No it'll go black, that's the carbon brushes running against it. It'll take a few weeks but it'll go black and be fine.
ah ok - always thought they were black when burnt out

Offline Hoover Master

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Re: Clutched Dyson DC04 - Motor Replacement Guide
« Reply #11 on: April 03, 2017, 08:02:33 PM »
I'm not really up on motors but if the Armature looked ok and the brushes looked ok while you were doing it then why would blow? That may be an obvious answer but oh well.
Excellent write up! :thumbsup:

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Re: Clutched Dyson DC04 - Motor Replacement Guide
« Reply #12 on: April 03, 2017, 08:37:46 PM »
I have no idea why it blew, but it was very annoying! It ran fine too, 5 minutes in it just went!

Shows why it's important to always thoroughly test a machine before sale!
Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Offline Hoover Master

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Re: Clutched Dyson DC04 - Motor Replacement Guide
« Reply #13 on: April 03, 2017, 08:46:33 PM »
It does. It's enjoyable to use them after refurb!

Online Madrat

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Re: Clutched Dyson DC04 - Motor Replacement Guide
« Reply #14 on: April 03, 2017, 10:20:23 PM »
I had an Amtex in a dc04 do the same thing, except it blew the armature off the shaft. Like you it had been refurbed and tested before it decided to do it  :angryman:

https://manchestervacs.co.uk/DysonForum/index.php/topic,1715.0.html

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