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Author Topic: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!  (Read 10895 times)

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Re: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« Reply #15 on: November 04, 2017, 12:04:04 AM »
The cogs and bearings pull out easily

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The belt guide unscrews, and has a little spring underneath

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The motor mount is not too clever either

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Unscrews for washing

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Motor ID

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Onto the cyclone now!



Take the bin off

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Take the bottom flap off

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Re: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« Reply #16 on: November 04, 2017, 12:08:09 AM »
The bin release rod can be unclipped easily

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And removed which is great as behind it is really gritty

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These manky seals pull out of the bottom flap

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The pre motor filter is actually quite clean

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The rubber seal pulls off

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The top ring unclips

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Inside shows it's not quite as spotless as it could be

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I spy plasterdust...

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Re: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« Reply #17 on: November 04, 2017, 12:13:55 AM »
With a firm lever in the right place, the bin flap release button pops out of the handle

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The spring pulls out from underneath the red button

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The cyclone handle unclips from the cyclone top, and the blue filter top unclips from that

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With another rubber seal around that

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*Don't do this, as it's an utter sod to reassemble* The 2 parts of the handle seperate, and release their little spring

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Moving down a bit, the bin to cyclone seal pulls off

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Next, release all the clips around the edge in turn

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Then on the last one there will be a CRACK as the assembly splits when the final clip lets go and covers you in dust...

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Re: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« Reply #18 on: November 04, 2017, 12:20:08 AM »
The locking tab for the bin has a little spring behind it, and although the tab won't come off easily, I didnt want to loose the spring so off it came

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With a small flatblade screwdriver, gently prise the shroud off the cyclone assembly. Be careful as it's properly flimsy when not attacked

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I found this a bit odd, the middle release rod spring could exit through a hole at the bottom of it's mounting bracket, so out it came on its own

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The inner cone top seal comes off

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Next, the foam gasket that runs around the little inner cyclones comes off with levering required all around for a bit

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More gentle levering required and this white plastic frame pops off. It's gripped on each cone so is a little time consuming, and you cant lever too hard or you'll break through it

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Being stuck on with plaster dust probably didnt help though

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Buried under all that lot, and all this lot are the screws that hold the top on



With all those removed, the top falls apart

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Re: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« Reply #19 on: November 04, 2017, 12:25:10 AM »
Revealing more white death

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The middle rod is removed now

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The two halves of the inner assembly are sealed with a foam gasket which pulls carefully off so it isnt torn. No sign of wear though, but it's hidden away unlike the foam gasket on a DC24/25/33

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Either way, THAT'S IT!

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Everything was soaked to dissolve the grime, then washed, polished, dried and laid out!

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And now, we get to put it all back together YEY!

Starting with the foam gasket

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Which only goes on a certain way, you have to line the notches tabs and screwholes up

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I went to refit the middle rod and spring

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Re: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« Reply #20 on: November 04, 2017, 12:40:37 AM »
But the spring came out the bottom, so I worried about that later

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I couldn't really photo the steps next, but basically take the now clean top cover, insert the middle part into the inner cone and screw it all back together!

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Pop the plastic cone frame on

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And it's foam gasket, paying attention to the locating tab on it too

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Inner cone tip seal on

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Shroud now!

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Which thanks to its complete lack of any rigidity when not on the machine is a complete pain, but eventually it clips on

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Bin securing latch spring on

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Re: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« Reply #21 on: November 04, 2017, 12:46:15 AM »
Connecting the 2 parts of the cyclone together is simple, except you need a tiny screwdriver to tease the little latch spring onto it's resting place before fully clipping the 2 parts together. Do-able with care though.

ALSO, we need to sort the middle latch spring. Before clipping the 2 parts together, insert the spring so it sits like this (it should just sit like this anyway as it's not under tension

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Once the two parts are clipped together, there's just enough space to push the tab round and it'll drop into the notch in the casing, and be tensioned!

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Top bin seal on

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We need to put the handle together now...

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Looking at the time stamp of these two pictures it took 17 minutes to do this! The parts need to twist slightly, but there's no room to twist. Slight anger did the trick in the end...

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Pop the seal back onto the filter cover

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And clip that into the handle

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Put the outer spring in

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Re: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« Reply #22 on: November 04, 2017, 12:50:12 AM »
Then push the release button in and check it operates fine

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Fit the handle to the cyclone and check the release mechanism still operates as it should, pushes the middle part down, springs back etc

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Pre filter next

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Pop the top cap onto the main frame, there's a matching thing to line up on here too

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Pop the seal onto that and drop it into the machine

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Clip the top down, then grab your flap

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This was a bit fiddly, but push the rubber seals back into place on the bottom flap

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Snap the bin release rod in

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And fit the flap to the bin using the under arm bear hug technique to squeeze the bin slightly and widen the locating tabs

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Re: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« Reply #23 on: November 04, 2017, 12:55:10 AM »
And fit the bin to the cyclone



And that's done! Check the release mechanism works properly again etc and one job is finished!

So we dive nose first into the next bit... Fit the cog mech holding plate to the brushroll motor

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Pop the spring in the belt tensioner locating block

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Then drop the plastic peg on and do the screw up

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Next, grab the main brushroll cog

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The bearing felt a little dry, so pop the black cover off the bearing with a tiny jewelers driver

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And pop a smear of grease in there

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Then pop the cap back on! No need to do both sides, the grease will work its way through in use

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Drop the cog into the housing, then fit the belt

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Re: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« Reply #24 on: November 04, 2017, 01:02:57 AM »
Fit the centre wheel and axle to the housing

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Pop the other side of the housing on

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Fit the rubber jacket to the top of the brushroll motor

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SHINEY

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First thing to fit is the wiring loom. Observe the correct orientation (guess what I had to do...)

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The motor retaining plate looks a little better now

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Fit the motor

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Drop the motor assembly into the head and check it's located properly

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Screw that down, then run the wires

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Re: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« Reply #25 on: November 04, 2017, 01:08:57 AM »
Run the wires around in their channel

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And plug them in! The plugs are different sizes so no fear of getting it wrong

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Pop the brushroll cogs on and screw them up

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Pop the little wiring loom cover onto the connecting neck

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Then fit the deflector plate and screw it down

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Grease the brushroll bearing end caps the same way as we did the brushroll cog

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Then screw them down

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On one side, the bearing stayed on the brushroll, and through fear of snapping the bit it pushes on to, I left it there. It was showing signs of ill health

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Re: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« Reply #26 on: November 04, 2017, 01:15:04 AM »
The brushroll and cog have a bit that need to line up

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Once you work that out the brushrolls slide on easily, and the end caps can be screwed down

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Drop the front bumper onto the head

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Next, pop the slider frame onto the sealing strip, with a lick of grease to try and make it easier to move, as I always find these things incredibly stiff to move from max to normal

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What follows was me finding out how fiddle it all is. The black frame sits behind these parts, wheras the sealing strip sits infront

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But you can't just drop the lot in, as it's recessed, so the black slider sits inside the frame almost...

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Eventually, I got it in, mainly by putting the black slider in, then one by one pulling each locating tab out and clipping the sealing strip on. Eventually it all dropped into place and just worked! Red slider got clipped on quick sharp

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Then the two halves were screwed together

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And with the baseplate latched shut, number 2 can be ticked off the list

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Re: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« Reply #27 on: November 04, 2017, 01:24:34 AM »
Don't fall asleep at the back there, final stage now!

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Drop the locating bar and big spring into the motor housing

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Then before it all pings out and takes your eye out screw the cover on

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Drop the motor rubber into the casing

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Time to start assembling the changeover valve

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To cure the sticky release valve this seems to have (the main reason it was so cheap I think), a smear of grease was deployed

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Slide this part in, and screw it from the other side

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Little teeny tiny damper now

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Re: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« Reply #28 on: November 04, 2017, 01:29:15 AM »
Screw the damper to it's frame

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More magic moving fluid

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And it slides in from the other side and screws up

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Next, grab the top half of the spine and throw the cable through it, using the existing pressure marks to line it up

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Line it up and check the cable falls where it's supposed to (I didn't check this on the DC40 from that thread and it was a right apin to sort



Once happy, screw it down

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I fitted the bottom cord hook here, but TBH don't bother and do it with the hose as it falls out alot...

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Pop the air path window on

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And feed the motor wire loom into the motor housing and make sure the seal fits snugly

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Re: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« Reply #29 on: November 04, 2017, 01:33:14 AM »
Grab the brushroll loom and run the wires behind this plastic part

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Fit the release valve into the lower part of the airflow duct

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Wire the motor up and drop it into the bottom mount we dropped in earlier

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Pop the fancase seal on and then fit the cover and screw it down

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This cord clamp needs fitting

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Pop the wheel assembly on

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Refit the tension spring

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Next, fit the cam that controls the brushroll switch

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Then the switch, and run the wires to it and connect them up

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