Author Topic: Dyson DC40 Mk1 (Pre EU) - Stripdown and Refurbishment (Read 91916 times)

beko1987 · « **Reply #15 on:** July 21, 2017, 12:21:48 am »

Up top now, and the very clean filter can be removed

And split

The carry handle unclips from the back to come off completely

The red release button and spring pop out of the carry handle

The handle is a bouncy one, the two halves given their spring by a, well, spring!

The clue vanity cap to mark the filter pops out

and it's seal can be removed

The bouncy handle separates

And we can get to the main cyclone!

beko1987 · « **Reply #16 on:** July 21, 2017, 12:26:33 am »

The top bin seal lifts off

And by popping the 4 tabs one can split the cyclone from the shroud

and remove the shroud and outer cyclones

OMG Plasterdust! I'm so happy to see this!

Dysons love plaster dust, I'm glad it's had some

Awful image but the shroud can be removed now, although it's VERY flexible when off, can barely hold it's own shape...

To the top half now, and the cyclone tip seal pops off the cone tips

And buried deep under all the shyte are some screws

Which when removed do this:

The very tip of the inner part of the cyclone has a rubber seal that mates to the suction channel under the bin

beko1987 · « **Reply #17 on:** July 21, 2017, 12:28:33 am »

And finally the foam gasket can be removed

and IT. IS. STRIPPED!

Everything was washed and dried

and polished, and ready for re-assembly

Which will follow on another day, because I'm tired, and need to go to bed, it's a work night!

Stay tuned for the 96 reassembly pictures!

ollivacguy · « **Reply #18 on:** July 21, 2017, 12:30:00 am »

That all looks a bit more complicated than a DC04 or something of similar Chassis/ design.

beko1987 · « **Reply #19 on:** July 21, 2017, 12:34:05 am »

Ooooh yes! It makes a dc24 seem very very simple!

Parwaz7862 · « **Reply #20 on:** July 21, 2017, 09:04:41 pm »

Ugh DC40 Mk1...

I'm waiting for the day you get a DC41- much easier to strip, assemble, better performance, etc! I just love them haha

Brilliant stripdown so far btw (as usual

)

beko1987 · « **Reply #21 on:** July 21, 2017, 09:09:04 pm »

Quote from: Parwaz7862 on July 21, 2017, 09:04:41 pm

Ugh DC40 Mk1...

I'm waiting for the day you get a DC41- much easier to strip, assemble, better performance, etc! I just love them haha

Brilliant stripdown so far btw (as usual )

Thanks! Sure I'll get a 41 one day!

Even though I did this refurb blind and with nothing to loose if it all went wrong, the pictures will hopefully help people pinpoint issues with their dc40s

dysondc16 · « **Reply #22 on:** July 22, 2017, 02:41:52 am »

Thanks a bunch beko for the stellar pics on this thread. I'm sure I will need this in the future

Not a big fan of the dc40 either, I only keep mine because it isn't bad on hard floors.

beko1987 · « **Reply #23 on:** July 23, 2017, 07:34:37 pm »

Right, let's carry this on a bit now I'm not falling asleep at the keyboard!

Everything was um, washed, polished, and um, ah yes

Dyson DC40 Mk1 (Pre EU) - Stripdown and Refurbishment

Virtual hi-five for the first person to type up the complete part list from that picture!

*sigh* I suppose it's time to put it together again! Cyclone first

Cyclone gasket fitted

Fuzzy end tip seal on

And the top part can be popped together and screwed down! I had to clean the heads of these screws out with a few bristles of a stiff brush, then they were much easier to do up!

The lower rubber gasket can be clipped onto all the tips now

The shroud can be clipped onto the lower cone

I got the red middle part of the bin release rod and spring together

beko1987 · « **Reply #24 on:** July 23, 2017, 07:39:29 pm »

Then battled to get the removal button spring back on, then the two cyclone halves clipped together without trapping the spring, the spring not being positioned right, the spring flying across the room or sometimes multiples of the above

Once that was done, the red middle part and spring had to go in. This is as much of a sod as a DC24 one is, and since I haven't found a foolproof way of doing it yet, after much swearing it sat correctly (it needs to be held out against the stopper, so it slides over the bin and not into it)

Then... buggar, I found this seal which had dropped out whilst washing

And yes, all the above had to be undone to fit the seal, which is actually a sod, I don't recommend removing this if you can help it

Red part sitting properly against the backing bit

That done, I could clip the cyclone handle together

Not forgetting it's spring

The filter cover seal gets re-fitted

And snapped into place under the handle

beko1987 · « **Reply #25 on:** July 23, 2017, 07:43:42 pm »

The top part of the whole bin flap rod sits over a spring which sits in the handle

The red part itself clips in, making sure all the various runners are aligned

Filter now, and the top seal gets fitted

Then the bracing cage

Then fitted

And the lid shut

Onto the other end of the assembly now, the bottom bin flap

Rubbered up for safety

Then fitted to the bin, and the red rod slid and clicked into place

beko1987 · « **Reply #26 on:** July 23, 2017, 07:48:55 pm »

And the cyclone assembly is done!

Brushroll housing now!

The cog and bearings were fitted to the housing

This was clipped to the brushroll motor and the belt fitted to stop it all falling apart

The middle brace and spring were added, then the whole lot screwed together quickly before the sping decided to go for a jog

The motor assembly was fed into the mounting plate, and the brushroll cogs fitted

and the middle wheel dropped into place

Housing now, and I snapped the base plate on

Now I knew how much force the wiring loom needed it was fitted very quickly

And the plug and wire cover refitted

beko1987 · « **Reply #27 on:** July 23, 2017, 07:55:21 pm »

The motor assembly was laid into place

And the screws on the top fitted

The motor cover and segmenting barrier were snapped on

And then screwed down, along with the wiring cover

Brushroll end caps next, and this took 2 attempts, because as I mentioned during disassembly, their handed...

See

A quick swap round had them screwed down nicely

Then the base plate (which by the way was full of fluff around the inside of the rubber membrane. It all started pouring out whilst I washed it, it moved about ALOT better after this, if your DC40/41/any of the modern dysons with a base plate like this start not working very well, check this!) ahem, was fitted

And the brushroll housing is finished!

beko1987 · « **Reply #28 on:** July 23, 2017, 08:02:14 pm »

Onto the motor now, and this part was blurry in real life, that's certainly not my camera doing that...

Then this latch was fitted

And the cover quickly bolted down

Inside, and the motor seal is fitted

The carbon brush removed from the motor again

which was fitted, carbon brush replaced, inner fancase seal fitted and the top screwed down!

Changeover valve now, and I put the rubber seal on

Fitted the spring to one side of the securing cage

And slid it into place on the internal hose

beko1987 · « **Reply #29 on:** July 23, 2017, 08:12:57 pm »

The other side, which actually holds it to the machine slid in place

And the whole thing slid into the chassis, screwed up and the springs fitted. I put a drop of glue on the small hole in the hose from the wooden skewer to fix that!

Next thing to do was to thread the spinal cord into place on the upper chassis (which turned out to be a mistake, but I think still the correct process, just pay more attention than I did to the markings from when the cable was fitted before to line it all up...)