Dyson & Sebo Vacuum Cleaner Repair & Advice Forums
Dyson Models => Second Generation "The Ball" Dysons. => Topic started by: beko1987 on November 02, 2017, 09:41:35 pm
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A few months ago now, an amazing ebay steal and a freecycle find had the back of my car looking like this after a lovely drive through oxfordshire one Sunday
[attachimg=1]
The Sebo X1 is already sold, the DC40 Mk1 is still here, but we already have a nice rebuild thread on one of those, so this is all about this:
[attachimg=2]
[attachimg=3]
[attachimg=4]
A Dyson DC41 Mk2 Erp for £5!
So on we go!
Cyclone Off
[attachimg=5]
Turn it on it's side, and remove the red clip holding the brushroll housing on
[attachimg=6]
[attachimg=7]
Drop the cable
[attachimg=8]
And release the hose
[attachimg=9]
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Which was lovely and clean!
[attachimg=1]
The wand unclips from the hose
[attachimg=2]
And the tools release button pops off
[attachimg=3]
As does the cover for the top cord hook screw
[attachimg=4]
The screw comes out, as does the spring behind it, and the hook itself then falls off the wand
[attachimg=5]
The hose also splits, and this will show how to split the hose end for repair too! Pop the plastic end cap off the hose cuff
[attachimg=6]
The rubber cuff pulls off the hose end
[attachimg=7]
At this point, you would cut the hose at the tear, remove the remains from this black cuff then glue and screw the hose back onto it!
Inside the plastic cuff is this white cover
[attachimg=8]
Underneath is the latch that holds it onto the wand
[attachimg=9]
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It's operated by this tiny spring
[attachimg=1]
It just pulls out of the hose cuff
[attachimg=2]
The main handle is clipped onto the chassis, and released by pushing this black latch in
[attachimg=3]
[attachimg=4]
The top cover and wand cover are held in with this locking tab
[attachimg=5]
And pull off when that is released
[attachimg=6]
Time to remove the tools and tool holder
[attachimg=7]
And pull the combi tool apart
[attachimg=8]
These 4 screws hold the switch cover in place
[attachimg=9]
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2 small tabs hold the switch cover on, and once removed it all looks like this
[attachimg=1]
With the two switches like this
[attachimg=2]
Pull all the connections apart
[attachimg=3]
And the mains cable can be removed
[attachimg=4]
The spinal cord can be pulled out this far for now
[attachimg=5]
Time to move down now, and remove the post motor filter cover
[attachimg=6]
[attachimg=7]
The filter had a fair bit of fluff in, but not heavily soiled etc
[attachimg=8]
It can be removed and cleaned up
[attachimg=9]
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The other wheel on the other side is bolted on. First you remove this cover a quarter of a turn with a pair of needle nose pliers
[attachimg=1]
The screw underneath can be removed with the same process
[attachimg=2]
And the shell lifted off
[attachimg=3]
The top vanity cover unscrews now
[attachimg=4]
Behind the non filter side sit these two washers, which will fall off if you dont remove them now
[attachimg=5]
The socket for the brushroll housing can be lifted up now it's not held in with the vanity cover
[attachimg=6]
[attachimg=7]
But you can't just take the wires out as they run behind this bit of plastic.
[attachimg=8]
Which you could probably just cut, or you could remove the connectors from the plastic block (they just lift out) and feed them through
[attachimg=9]
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With that, the holder is free of wiring
[attachimg=1]
And we can remove the screws holding the back of the filter housing on
[attachimg=2]
[attachimg=3]
Next layer now, these screws on one side
[attachimg=4]
And on the other side, the wheel assembly needs to be rotated to uncover the screws
[attachimg=5]
The internal hose is held on with a tiny screw
[attachimg=6]
and once removed the wheel assembly can be lifted off
[attachimg=7]
On the filter side, we find the same 2 spacer washers, but within a plastic cage
[attachimg=8]
Under the wheel assembly is 4 screws
[attachimg=9]
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With those removed the internal hose assembly is seperated from the wheel assembly
[attachimg=1]
The pivot lock unclips from the internal hose assembly
[attachimg=2]
Like so
[attachimg=3]
The internal hose starts to split apart, but the end is glued together and I have no desire to mess about with that so left it alone!
[attachimg=4]
This screw holds a plastic cog to the wheel assembly
[attachimg=5]
[attachimg=6]
These two roller wheels pop out
[attachimg=7]
Next layer now, the suction duct
[attachimg=8]
This rear screw is part of it too
[attachimg=9]
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Which then lifts off
[attachimg=1]
The cyclone seal lifts off
[attachimg=2]
This reveals the PCB, which is held in with 2 small screws
[attachimg=3]
[attachimg=4]
[attachimg=5]
Remove all the wires and hope this massive capacitor doesn't short out and explode
[attachimg=6]
Next layer now, the underside of the suction duct!
[attachimg=7]
Terrible shot but release the wires that run through it as you remove it
[attachimg=8]
The release valve is hiding in this layer too
[attachimg=9]
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The wires sit like so underneath
[attachimg=1]
The brushroll loom can be removed now
[attachimg=2]
Aha, we can see the motor housing now
[attachimg=3]
This is the brushroll switch, that makes the brushroll go on and off when you recline the vac
[attachimg=4]
Looking at this picture, I've lied at some point, as THIS is the flipping wheel housing, that other part must have been something else. Let's call it the yolk carriage assembly or something!
WHEEL ASSEMBLY... Remove the small screw holding this spring on
[attachimg=5]
WHEEL ASSEMBLY off
[attachimg=6]
Fancase cover now
[attachimg=7]
[attachimg=8]
Unlike a DC40, the motor just lifts out!
[attachimg=9]
And that's it for tonight folks, got to be up early! Moar soon, only another 242 pictures to go...
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Time for a bit more!
We have the motor out now
[attachimg=1]
From it's dusty place
[attachimg=2]
The motor loom pops out of the access hole
[attachimg=3]
[attachimg=4]
I popped the access cover flap off
[attachimg=5]
Time to get the changeover valve off now
[attachimg=6]
First off is a tiny damper valve, just removed from the body of the machine now
[attachimg=7]
Whilst doing this, the bottom cord hook fell off, as it's just held in with the hose, which is now removed
[attachimg=8]
We are now hampered by the chassis, so let's remove the screws and get that out of the way!
[attachimg=9]
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The spinal cord can be removed now as well, as it's held in with the joint
[attachimg=1]
Back to the valve now, the part that holds the damper valve is held in with this screw
[attachimg=2]
Then it lifts out
[attachimg=3]
The damper can be removed with a tiny screw
[attachimg=4]
The damper itself splits down
[attachimg=5]
The little hose and pivoting part lifts out now, with a bit of a fiddle with the hose
[attachimg=6]
[attachimg=7]
Another mounting bracket unscrews
[attachimg=8]
Inside the motor bucket is a rubber mount
[attachimg=9]
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The locking part for the recline mechanism sits under this cover
[attachimg=1]
[attachimg=2]
It all just lifts out
[attachimg=3]
That's the main part of the machine done! Time to move on to the cleanerhead!
[attachimg=4]
Looking lovely
[attachimg=5]
The baseplate unclips and hinges forward
[attachimg=6]
Said hinge is held together with some screws
[attachimg=7]
Which makes it much easier
[attachimg=8]
We can look at the Erp bit now, the adjustable mechanism for min and max. It starts with the red slider button that lifts and lowers the rubber front
[attachimg=9]
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The red slider pops out
[attachimg=1]
With a bit of fiddling, the rubber part unclips from the baseplate
[attachimg=2]
The black slider mount unclips from the rubber part
[attachimg=3]
As per all of these types of floating baseplate I've seen, the rubber part is jammed up with crud... Deal with that later
[attachimg=4]
Back to the main head, the front bumper lifts off
[attachimg=5]
The brushrolls are held in with the end caps being screwed down
[attachimg=6]
And pull out with the screws removed
[attachimg=7]
The end caps are screwed into the brushroll
[attachimg=8]
and prise off easily once the screw is removed
[attachimg=9]
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To show the bearing underneath the end cap
[attachimg=1]
Under the brushroll, there is a deflector plate that slides out
[attachimg=2]
It's quite clean
[attachimg=3]
Under the deflector plate are the screws that hold the motor cover on
[attachimg=4]
To remove the motor parts, the cogs that drive the brushrolls have to be unscrewed and pulled off
[attachimg=5]
The motor lifts out then, but is hindered by the head loom
[attachimg=6]
Quick shot of how the wires run before we unplug them
[attachimg=7]
The motor lifts out
[attachimg=8]
Typical of the brushroll motors from the DC25 onwards
[attachimg=9]
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More filth
[attachimg=1]
Time to remove this little loom
[attachimg=2]
The wires handily just slip out
[attachimg=3]
That's the brushroll housing done!
[attachimg=4]
Onto the drive mechanism now
[attachimg=5]
Some screws to undo
[attachimg=6]
Nothing wrong here
[attachimg=7]
The middle wheel falls out now, held in with the 2 sides of the casing
[attachimg=8]
The little belt slips off
[attachimg=9]
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The cogs and bearings pull out easily
[attachimg=1]
The belt guide unscrews, and has a little spring underneath
[attachimg=2]
The motor mount is not too clever either
[attachimg=3]
Unscrews for washing
[attachimg=4]
Motor ID
[attachimg=5]
[attachimg=6]
Onto the cyclone now!
[attachimg=7]
Take the bin off
[attachimg=8]
Take the bottom flap off
[attachimg=9]
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The bin release rod can be unclipped easily
[attachimg=1]
And removed which is great as behind it is really gritty
[attachimg=2]
These manky seals pull out of the bottom flap
[attachimg=3]
[attachimg=4]
The pre motor filter is actually quite clean
[attachimg=5]
The rubber seal pulls off
[attachimg=6]
The top ring unclips
[attachimg=7]
Inside shows it's not quite as spotless as it could be
[attachimg=8]
I spy plasterdust...
[attachimg=9]
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With a firm lever in the right place, the bin flap release button pops out of the handle
[attachimg=1]
The spring pulls out from underneath the red button
[attachimg=2]
The cyclone handle unclips from the cyclone top, and the blue filter top unclips from that
[attachimg=3]
With another rubber seal around that
[attachimg=4]
*Don't do this, as it's an utter sod to reassemble* The 2 parts of the handle seperate, and release their little spring
[attachimg=5]
Moving down a bit, the bin to cyclone seal pulls off
[attachimg=6]
Next, release all the clips around the edge in turn
[attachimg=7]
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...
[attachimg=8]
[attachimg=9]
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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
[attachimg=1]
With a small flatblade screwdriver, gently prise the shroud off the cyclone assembly. Be careful as it's properly flimsy when not attacked
[attachimg=2]
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
[attachimg=3]
The inner cone top seal comes off
[attachimg=4]
Next, the foam gasket that runs around the little inner cyclones comes off with levering required all around for a bit
[attachimg=5]
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
[attachimg=6]
Being stuck on with plaster dust probably didnt help though
[attachimg=7]
Buried under all that lot, and all this lot are the screws that hold the top on
[attachimg=8]
With all those removed, the top falls apart
[attachimg=9]
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Revealing more white death
[attachimg=1]
The middle rod is removed now
[attachimg=2]
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
[attachimg=3]
Either way, THAT'S IT!
[attachimg=4]
[attachimg=5]
Everything was soaked to dissolve the grime, then washed, polished, dried and laid out!
[attachimg=6]
And now, we get to put it all back together YEY!
Starting with the foam gasket
[attachimg=7]
Which only goes on a certain way, you have to line the notches tabs and screwholes up
[attachimg=8]
I went to refit the middle rod and spring
[attachimg=9]
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But the spring came out the bottom, so I worried about that later
[attachimg=1]
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!
[attachimg=2]
[attachimg=3]
Pop the plastic cone frame on
[attachimg=4]
And it's foam gasket, paying attention to the locating tab on it too
[attachimg=5]
Inner cone tip seal on
[attachimg=6]
Shroud now!
[attachimg=7]
Which thanks to its complete lack of any rigidity when not on the machine is a complete pain, but eventually it clips on
[attachimg=8]
Bin securing latch spring on
[attachimg=9]
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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
[attachimg=1]
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!
[attachimg=2]
[attachimg=3]
Top bin seal on
[attachimg=4]
We need to put the handle together now...
[attachimg=5]
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...
[attachimg=6]
Pop the seal back onto the filter cover
[attachimg=7]
And clip that into the handle
[attachimg=8]
Put the outer spring in
[attachimg=9]
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Then push the release button in and check it operates fine
[attachimg=1]
Fit the handle to the cyclone and check the release mechanism still operates as it should, pushes the middle part down, springs back etc
[attachimg=2]
Pre filter next
[attachimg=3]
Pop the top cap onto the main frame, there's a matching thing to line up on here too
[attachimg=4]
Pop the seal onto that and drop it into the machine
[attachimg=5]
Clip the top down, then grab your flap
[attachimg=6]
This was a bit fiddly, but push the rubber seals back into place on the bottom flap
[attachimg=7]
Snap the bin release rod in
[attachimg=8]
And fit the flap to the bin using the under arm bear hug technique to squeeze the bin slightly and widen the locating tabs
[attachimg=9]
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And fit the bin to the cyclone
[attachimg=1]
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
[attachimg=2]
Pop the spring in the belt tensioner locating block
[attachimg=3]
Then drop the plastic peg on and do the screw up
[attachimg=4]
Next, grab the main brushroll cog
[attachimg=5]
The bearing felt a little dry, so pop the black cover off the bearing with a tiny jewelers driver
[attachimg=6]
And pop a smear of grease in there
[attachimg=7]
Then pop the cap back on! No need to do both sides, the grease will work its way through in use
[attachimg=8]
Drop the cog into the housing, then fit the belt
[attachimg=9]
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Fit the centre wheel and axle to the housing
[attachimg=1]
Pop the other side of the housing on
[attachimg=2]
Fit the rubber jacket to the top of the brushroll motor
[attachimg=3]
SHINEY
[attachimg=4]
First thing to fit is the wiring loom. Observe the correct orientation (guess what I had to do...)
[attachimg=5]
The motor retaining plate looks a little better now
[attachimg=6]
Fit the motor
[attachimg=7]
Drop the motor assembly into the head and check it's located properly
[attachimg=8]
Screw that down, then run the wires
[attachimg=9]
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Run the wires around in their channel
[attachimg=1]
And plug them in! The plugs are different sizes so no fear of getting it wrong
[attachimg=2]
Pop the brushroll cogs on and screw them up
[attachimg=3]
[attachimg=4]
Pop the little wiring loom cover onto the connecting neck
[attachimg=5]
Then fit the deflector plate and screw it down
[attachimg=6]
Grease the brushroll bearing end caps the same way as we did the brushroll cog
[attachimg=7]
Then screw them down
[attachimg=8]
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
[attachimg=9]
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The brushroll and cog have a bit that need to line up
[attachimg=1]
Once you work that out the brushrolls slide on easily, and the end caps can be screwed down
[attachimg=2]
Drop the front bumper onto the head
[attachimg=3]
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
[attachimg=4]
What follows was me finding out how fiddle it all is. The black frame sits behind these parts, wheras the sealing strip sits infront
[attachimg=5]
But you can't just drop the lot in, as it's recessed, so the black slider sits inside the frame almost...
[attachimg=6]
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
[attachimg=7]
Then the two halves were screwed together
[attachimg=8]
And with the baseplate latched shut, number 2 can be ticked off the list
[attachimg=9]
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Don't fall asleep at the back there, final stage now!
[attachimg=1]
Drop the locating bar and big spring into the motor housing
[attachimg=2]
Then before it all pings out and takes your eye out screw the cover on
[attachimg=3]
Drop the motor rubber into the casing
[attachimg=4]
Time to start assembling the changeover valve
[attachimg=5]
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
[attachimg=6]
Slide this part in, and screw it from the other side
[attachimg=7]
Little teeny tiny damper now
[attachimg=8]
[attachimg=9]
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Screw the damper to it's frame
[attachimg=1]
More magic moving fluid
[attachimg=2]
And it slides in from the other side and screws up
[attachimg=3]
Next, grab the top half of the spine and throw the cable through it, using the existing pressure marks to line it up
[attachimg=4]
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
[attachimg=5]
Once happy, screw it down
[attachimg=6]
I fitted the bottom cord hook here, but TBH don't bother and do it with the hose as it falls out alot...
[attachimg=7]
Pop the air path window on
[attachimg=8]
And feed the motor wire loom into the motor housing and make sure the seal fits snugly
[attachimg=9]
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Grab the brushroll loom and run the wires behind this plastic part
[attachimg=1]
Fit the release valve into the lower part of the airflow duct
[attachimg=2]
Wire the motor up and drop it into the bottom mount we dropped in earlier
[attachimg=3]
Pop the fancase seal on and then fit the cover and screw it down
[attachimg=4]
This cord clamp needs fitting
[attachimg=5]
Pop the wheel assembly on
[attachimg=6]
Refit the tension spring
[attachimg=7]
Next, fit the cam that controls the brushroll switch
[attachimg=8]
Then the switch, and run the wires to it and connect them up
[attachimg=9]
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Next, run all the wires where they need to go under the airflow duct
[attachimg=1]
Then, fit the first half of the airflow duct, running the wires through their holes
[attachimg=2]
Pop the PCB in, screw it down and populate the wires
[attachimg=3]
Fit the seal to the cyclone locating part, then fit the top half of the airflow duct and screw it down
[attachimg=4]
Grab the part I kept calling the wheel housing earlier, which is actually probably maybe the yolk assembly, and fit the 2 rollers
[attachimg=5]
Fit the white cog
[attachimg=6]
Next, fit the stabilizer lock bar to the internal hose bracket
[attachimg=7]
[attachimg=8]
Screw this to the other bit
[attachimg=9]
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Clip the washers and cradle to the wheel axle
[attachimg=1]
Then drop the whole lot onto the machine
[attachimg=2]
And do up all the screws, manipulating it about as it need to be manipulated
[attachimg=3]
[attachimg=5]
Pull the internal hose out and secure it in place at the top
[attachimg=4]
Fit the post motor filter back plate and hide all those nasty screws
[attachimg=6]
Next, find the brushroll plug cover and feed the wires under the plastic part
[attachimg=7]
Wire it all back up
[attachimg=8]
And fit it into place
[attachimg=9]
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With that, you can recline the machine if it's not already, and slide the top cover on
[attachimg=1]
Then, fit a wheel!
[attachimg=2]
Pop the post motor filter back on
[attachimg=3]
Then fit the other wheel
[attachimg=4]
Up top now, and fit the wiring to where it needs to go, plugging it in here and there
[attachimg=5]
Pop the switch covers together
[attachimg=6]
[attachimg=7]
Then fit the switch cover to the chassis, checking switch operation once screwed together
[attachimg=8]
Tools back on!
[attachimg=9]
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Wand handle next
[attachimg=1]
[attachimg=2]
[attachimg=3]
Popped that onto the cleaner
[attachimg=4]
Hose now!
[attachimg=5]
Inner red locking ring and spring fitted now
[attachimg=6]
White cover clipped on (I think this stops the red part pinging out and it all jamming up if the hose is pulled on the wand)
[attachimg=7]
Push the outer rubber collar onto the inner black collar, lining up the tabs
[attachimg=8]
Then clip the end part onto all of that
[attachimg=9]
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Hose is a bit cleaner for a spin through the washing machine
[attachimg=1]
Next, fit the stupid bottom cord hook, then wipe the smile off it's smug stupid falling out face by fitting the hose, trapping it forever
[attachimg=2]
Blimey, 1 SCREW LEFT :king:
[attachimg=3]
Which sits under all this
[attachimg=4]
Clunk, Click
[attachimg=5]
and it's done!
[attachimg=6]
[attachimg=7]
[attachimg=8]
[attachimg=9]
So there we have it, the first ever Dyson DC41 Mk2 stripdown thread probably anywhere, and since Dyson do not release the service manuals, probably the only place you will find the info!
I hope this helps people who want to fix or refurbish their own machines, collectors have a good ogle at the inside of one, and people in the trade who will do what I will do, and in the future follow this thread with their own basket case model sat on the bench!
As always, thanks for reading! I'm off to bed.
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Epic. :bow:
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Thanks for taking the time and effort on this one.
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Much appreciated, as I have on sitting requiring a main motor. :thumbsup:
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Don't know what it is but even with this fantastic thread noting interests me at all about these newer dysons, I just think there to over complicated for no apparent reason.
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I'm literally speechless. First of all I wouldn't even know how to take it apart but then to put it all together, man ..
(https://manchestervacs.co.uk/DysonForum/index.php?action=dlattach;topic=3329.0;attach=17173;image)
I would probably sit and cry if I had to put it all together :underchair:
It's unbelievable, I'm so impressed. :bow: :bow: :bow: :thumbsup: