Author Topic: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb! (Read 55755 times)

beko1987 · « **Reply #15 on:** November 03, 2017, 10:04:04 pm »

The cogs and bearings pull out easily

The belt guide unscrews, and has a little spring underneath

The motor mount is not too clever either

Unscrews for washing

Motor ID

Onto the cyclone now!

Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!

Take the bin off

Take the bottom flap off

beko1987 · « **Reply #16 on:** November 03, 2017, 10:08:09 pm »

The bin release rod can be unclipped easily

And removed which is great as behind it is really gritty

These manky seals pull out of the bottom flap

The pre motor filter is actually quite clean

The rubber seal pulls off

The top ring unclips

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

I spy plasterdust...

beko1987 · « **Reply #17 on:** November 03, 2017, 10:13:55 pm »

With a firm lever in the right place, the bin flap release button pops out of the handle

The spring pulls out from underneath the red button

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

With another rubber seal around that

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

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

Next, release all the clips around the edge in turn

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...

beko1987 · « **Reply #18 on:** November 03, 2017, 10:20:08 pm »

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

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

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

The inner cone top seal comes off

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

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

Being stuck on with plaster dust probably didnt help though

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

beko1987 · « **Reply #19 on:** November 03, 2017, 10:25:10 pm »

Revealing more white death

The middle rod is removed now

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

Either way, THAT'S IT!

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

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

Starting with the foam gasket

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

I went to refit the middle rod and spring

beko1987 · « **Reply #20 on:** November 03, 2017, 10:40:37 pm »

But the spring came out the bottom, so I worried about that later

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!

Pop the plastic cone frame on

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

Inner cone tip seal on

Shroud now!

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

Bin securing latch spring on

beko1987 · « **Reply #21 on:** November 03, 2017, 10:46:15 pm »

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

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!

Top bin seal on

We need to put the handle together now...

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...

Pop the seal back onto the filter cover

And clip that into the handle

Put the outer spring in

beko1987 · « **Reply #22 on:** November 03, 2017, 10:50:12 pm »

Then push the release button in and check it operates fine

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

Pre filter next

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

Pop the seal onto that and drop it into the machine

Clip the top down, then grab your flap

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

Snap the bin release rod in

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

beko1987 · « **Reply #23 on:** November 03, 2017, 10:55:10 pm »

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

Pop the spring in the belt tensioner locating block

Then drop the plastic peg on and do the screw up

Next, grab the main brushroll cog

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

And pop a smear of grease in there

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

Drop the cog into the housing, then fit the belt

beko1987 · « **Reply #24 on:** November 03, 2017, 11:02:57 pm »

Fit the centre wheel and axle to the housing

Pop the other side of the housing on

Fit the rubber jacket to the top of the brushroll motor

SHINEY

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

The motor retaining plate looks a little better now

Fit the motor

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

Screw that down, then run the wires

beko1987 · « **Reply #25 on:** November 03, 2017, 11:08:57 pm »

Run the wires around in their channel

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

Pop the brushroll cogs on and screw them up

Pop the little wiring loom cover onto the connecting neck

Then fit the deflector plate and screw it down

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

Then screw them down

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

beko1987 · « **Reply #26 on:** November 03, 2017, 11:15:04 pm »

The brushroll and cog have a bit that need to line up

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

Drop the front bumper onto the head

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

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

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

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