Hoover Junior U1040 - January 1980 - Assembly, Repair and Refurb for Hooverlux.

[beko1987]

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I was contacted a while ago by Hooverlux, some of you on Youtube might know him! (well, I say contact, we speak almost daily, but you know...) about a Hoover Junior he was having issues with...

So I said lob it all in a box and send it over!

And he did!

I assembled it in the dark so I knew what I had to deal with

Then set about making it run!

It took a whole spares machine to replace the armature (and other bits as we shall see later) and make it run!

So wahey, one working vacuum! Best make it look pretty...



The handle bolt on this style Junior also incorporates the cord clip



Took the handle off the, er, handle!



Lower handle off next



And the lower cable guide removed



Mmmm tasty...



Bag flange off



And around to underneath



Talking of the man himself, he appeared on my laptop!

[beko1987]

Wiring cover off



Mains cable off



Someone's been here before... lots of the screws are utterly  ed



With the cable removed, I could pull the guide off



Handle bail now



The two front screws have the wheels off



Which can then be split



Handle bail next



Which is utterly worn out

[beko1987]

We need most of it though, so apart it comes!



This bit is scrap though



These bits just rusty



Baseplate next



Which unscrews on these modern ones



Needs cleaning up



Brushroll now, with excellent brush strips!



Pull it apart

[beko1987]

Both brushroll bearings were utterly ruined



Brushroll apart



Furniture guard apart



Time to hoik the motor out





And remove the switch. The switch pedal is pivoted on this plastic bar, which pulls out



Then the pedal lifts off



This dimple in the bar keeps everything in order



Underneath we have a springy bar

[beko1987]

Which unscrews in 2 parts



The switch can then be removed



The filthy cable protectors removed



The switch doesnt seem to come out of the plastic frame so together it stays!



Popped the cable exit grommit out of the hood



And moved on to the front, where the front wheels are



Split those down



Yummy

[beko1987]

Next out is the main firewall, and it's nice fluffy pillow



Delightful



That's the original machine pretty much apart bar a few things, so now we need to get the parts we need from the donor machine!



Which apart from the motor bits also include the firewall, handle bail...

And screws!





Luckily the paint is almost the same shade



But the handle bail not as worn



No stuck screw in this firewall, although sadly it's plastic not metal, but I checked with the great ginger welshman and he was fine with it



It just needed a smidge of adjustment with a hammer to feed the headlight cable through

[beko1987]

Back to the original vac now, and the headlight lens screw snapped on Dorian when he tried to get it off, so I removed the metal bush



and the remains of the rusty screw



With careful application of some massive pliers the rusty stub did unscrew from the bush



This meant I could strip the headlight down



2 screws inside to hold the lens on



and done!



Motor now, as I only got it running, not fettled!

Not many wires left on it now





Top carbon is good

[beko1987]

Off with the screws



And off with the cover



To reveal this!



Rear bearing clamp off first



Then the front bearing clamp, and supressor screws and out t all pops!



Front bearing clamp had a nice compacted layer of dirt under it



Carbon holders out



Coil off the armature



Fan off

[beko1987]

Pop the front bearing off



And it's nearly done!



I just forgot the bag fill tube!





There!

All was washed and dried, and I tickled the metalwork with the wire brush



And gave the brushroll a blow over with new paint



Time to re-assemble, so first, a nice bead of almost gone too hard tigerseal on the hood



The firewall was fitted and screwed down and left to cure whilst I got on with other stuff



Mainly throwing the motor back together! I fitted a new front bearing as the old one didn't clean up very well, and just oiled the rear one

[beko1987]

Because we are going from newer style carbon brush holders to older style ones, and the connector snapped off we need to pop a ring terminal on





Then pop the cover on



Fit the short wires that replace the supressor run



Then grab the dried plastics (and cured hood)



Lay it out a bit



And give it a small tickle with the rotary polisher!

Then onto re-assembly, starting with the height adjustment knob

[beko1987]

Now I've never actually had a U1040 apart before, let alone back together and whilst everything else is standard junior fare, this was not. Luckily, I happen to have a service manual! (scan is on my blog if anyone needs it!)



I also replaced the perished rubber seal on the bag flange with a nice layer of silicone



And moved onto assembling the lens







Then I pushed the metal bush back in for the lens screw, and popped a small dribble of glue around the edges, which capilliaried in nicely



We have this now



Time to pop the front wheels together



Which look a bit cleaner

[beko1987]

And fitted



Switch now



Cable protectors fitted



And the switch can be clipped into place



Metal spring



Switch cover



And the plastic peg



Bumper on now



Then the cable exit grommit can go in

[beko1987]

Time to fill a hole!



Wire the switch up



I then had an 'Oh Sh!t' moment as I remembered I had not made a hole for the lens wiring... So out with the drill



And the purple cable guard snaps into place



Smear of silicone on both ends to seal it up, and the bulb holder and wires can be fitted



And wired up



Brushroll now!



Nice new bearings



And lovely!

[beko1987]

I fitted a new belt and popped the belt cover on



Then fitted the baseplate



A new bulb was needed, and luckily I had a podgy round one in my stash!



The lens cover can then be fitted



And a screw that ever so nearly perfectly fits to hold it in!



That's a bit better, bit more shiney...



Handle bail goes back together with it's new shell





And fitted to the cleaner

[beko1987]

Rear wheels next



Which were a bit cleaner



Then to the cable, and Dorian gave me a massive roll of new flex, so he could use it without having to change plugs so often



Lazy, but I fitted it anyway, and it saved me cleaning the cable up!



With the cable fitted to the motor, the wiring cover can go on





The lower handle can go on and the wire fed up



Then the upper handle and more wire feeding



Then it was on with the first of many layers of wax to lush the shine up