Dyson DC40 Mk1 (Pre EU) - Stripdown and Refurbishment

[beko1987]

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The other month, I was lucky enough to be given a DC40 Mk1 from a colleague at work.

So, naturally, it needed to be stripped down and refurbished!

Before that, however, I needed to get it working. The changeover valve was jammed up with a long cocktail stick. I neglected to take photos of it in place, but I pulled it out, and the changeover valve worked once more!



Next was the clogged brushroll housing (a common issue, one that I have fixed a few times before on other peoples machines!



The suction inlet is so narrow it blocks up very easily, and build up some more until it clogs fully



It worked well after this. I even got the box from their new cleaner, a DC40 Mk2!



However, there was a bigger issue with the machine



The yolk pivot stop was snapped off, so the machine fell over very easily, especially when using the tools!



Luckily, it was still under warranty with Dyson! So I told a white fib which results in it being registered to my Mum, who had bought it brand new in 2013 but lost all the paperwork, but really loves her Dyson, uses it every day etc, and a nice but apparently rushed man came round and replaced it within 30 minutes!



I then meant to use it for my vacuum for May, but TBH forgot it was at Mums and only used it for 2 weeks... Mum used it quite alot though, she almost liked it

https://www.youtube.com/watch?v=5IF8WGDtXUc&t=33s

https://www.youtube.com/watch?v=SHS6y-n7JT8&t=201s

Fun now over, it's time to get to work!

Cyclone off



Drop the cable

[beko1987]

With that off the horrible wand can come off



I don't know if the red part comes off, I doubt it though. The tool latch pops out though, along with it's little spring



The top cord hook is removed by popping the screw cover off



and removing the screw and then spring underneath



Hose now, it's removed by releasing the red catch then pulling upwards



Different angle showing the latch part of the red bit



And off, into the washing machine it went!



Tools now!



All you can really do is pull the dusting brush off the crevice tool!

[beko1987]

I did not know this until this point, but pushing on this catch here



releases the top handle!



George from here then pointed out on facebook that how did I think it went in a box shorter than it?...

The cap and cover can be removed by lifting this tab up under here



Then lifting it off



The wand cap snaps off with a little twist



It's easier to photograph now!



Behind the switches are 4 screws, which need to be removed



Then 2 plastic tabs which need to be gently released



The switch housing can then be removed

[beko1987]

We get asked about how this all fits together alot in the DC24 and 25 room, as if you yank it too hard it all falls out, so I made sure I took a really clear image of this bit!



The switch covers themselves just lift out



And the springs and white arm lift out

I got this part to move



But not come out so I left it be

Now we can remove the switches themselves



Lift the switches out, and disconnect the middle red brushroll reset wire



Then unplug everything else, the blue wire being connected up under this junction box.



Around the back, the lower cord hook lifts off the hose entry point



And the spinal cord can be withdrawn from the top of the cleaner



I did try to remove this seal, but it's glued on good and proper, so left it.

[beko1987]

The tool holder is removed by lifting a little tab and sliding it upwards



Time to remove the cleanerhead now



Removing the red clip allows the cleanerhead to fall off onto your foot 



Remove the post motor filter



And then move onto the other side. The outer cover twists off half a turn (and you can tell the Dyson man has been here before...)



Revealing this damaged black 'nut'



Which can be unscrewed with a pair of long nosed pliers



Voila!



It now won't stand up easily though...

[beko1987]

These two metal washers sit under the non filter side of the ball on the screw thread



I laid the machine down now



And reclined it back, which caused this piece to fall out



Which was a pain as I had no idea where it came from or how it fitted on. We'll worry about that later...

I took the post filter backplate off now



Then undid these two screws here



And these 3 here, which are only visible if the housing is rotated just so



This allows the yolk housing to be removed



But wait, the yolk wiring loom (which is where that random part came from) is still connected



The wiring plug lifts out of its place



and it is apart!

[beko1987]

The post filter side of the assembly has this black plastic cage over the rod, held in with a screw



Once removed it reveals 2 more metal washers



This is the brand new yolk pivot stop bar and it's spring



And this shows the position of the clear cog part before we remove it





Like so!

The internal hose that sits in the yolk pops out via a securing tab



These 2 metal roller wheels aid the 2 ball halves to spin smoothly



And the yolk is stripped down. Back to the main machine!



Already removed by this picture, the top vanity cover slides forward and off, revealing the PCB cover

[beko1987]

Which itself is held on with some screws





Revealing the quite tight PCB



First out is the cleanerhead loom, which plugs in bottom left



The other end of the loom opens up and allows the individual wires to be removed



Back to the PCB now and I just started pulling wires...



This right angled brown first



Then this straight brown which connected to the black wire to the motor



Then the blue wire which connected to the double white

[beko1987]

At this stage I lifted the PCB out, one last white wire remaining



One PCB



Some screws later and the PCB cage, which also turns out to be the entire siction duct from the motor to the bottom of the cyclone (almost exactly the same setup as the DC15, with the PCB being cooled with the main airflow path of the machine. Great when it's running cool, not so great when it clogs up and heats up...)





The cyclone seal can be lifted off at this point



Nestled within the PCB housing is the release valve. A standard DC24 type affair, a slight turn to unlock the cap and out it comes



This chap here is the Brushroll switch.



looks identical to a DC25 one...

It lifts out, along with the white lever



Which has a spring behind it that looks like it does above!

Next up is the spring that attaches to the wheels, and makes them flick up and down with the reclining mechanism

[beko1987]

With this removed, the wheels lift away from the main chassis too



The airpath rodding cover pops off now



Then 5 screws later the motor comes out!



As does the spinal cord from the base of the chassis



Leaving the motor for now, the changeover valve is next, and this spring needs to be removed, and the grey part lifting off



This black peice with the single screw clamps the changeover valve hose in place, and can be removed



On the other side, these two screws hold the assembly from this side



Then the other side is held in with this screw



The whole assembly lifts out now

[beko1987]

Remove the spring from the holding bracket



And pull the other bracket out from the end of the hose. I took the seal off too



That is the chassis fully stripped! Onto the motor now



Remove the screws holding the top cover down



The fancase seal lifts out of this cover



Then the motor lifts out of the housing, youll need to pull the sealing grommit out of the housing too with its wires. Except it doesn't... It won't come out AT ALL, so a carbon brush, the one you can get to with the motor fitted has to be removed to get the motor out of the housing!



Motor ID. DC25?



The top mount sits in the top of the housing



This black sliding part (I think it has something to do with the wheels) is unscrewed from the motor housing

[beko1987]

Revealing a locking latch and a ruddy strong spring



Which just lift out



This white lever (the purpose of which I have forgotten...) is removed with one screw, noting the blurry orientation of the spring...



Naked



We've filled up a flipping screw card already!



But we aren't done yet!



Time for the cleanerhead, I hear you cheer!



(What's that? No one's cheering? Well tough!) I cracked out some sugar and tea, and carried on



Baseplate off

[beko1987]

I did look into separating the floating baseplate, but even with the tabs unlatched, the rubber glued the 2 parts together, and if I tore that it would be game over, so I left it whole



Brushrolls removed with a half twist and a pull and 2 screws either end... Cross head too, the only ones on the whole damn machine!



The end caps (which ARE handed by the way) can be removed by undoing the centre screw



and pull off, revealing the delightful underneath!



Onto the motor now, and not really knowing where to start I just undid all the screws that looked like they held the motor housing to the cleanerhead



This trim piece came off too



As did the cover



Dr Johnson, I presume?



In amongst removing all the screws this sealing/deflector plate lifts out

[beko1987]

I unplugged the wires from the motor, and lifted the whole housing out from the cleanerhead



The small loom that takes the power from the cleanerhead join to the motor lifts out of it's circular groove



and the plug can be removed from the mounting piece. But the plugs don't come apart any further



Just as I was about to give up and jsut wash the wires with the head, I found the white plug just about squeezes through the hole, so can be removed



The front bumper snaps off



To remove the motor from its mounting plate, the brushroll cogs have to be unscrewed from the gearbox



Which then allows the unit to be withdrawn. Some more screws on the casing



Split it open even further



The cog part pulls carefully out of the outer housing, bringing the bearing with it

[beko1987]

Belt ID, although I can't imagine it'll ever break or get damaged



Finally the motor pops out of the housing in the same way a DC24/5 one does from it's housing!



I de-fluffed it



This piece does come out, it just sits here like this, the internal spring sits over it. Pic for orientation id



Cyclone next!



Bin off



Bottom flap off



Red release rod popped out of the channels on the side of the bin



And the seals pulled from the bottom flap