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Author Topic: DC 41 Motor replacement  (Read 2075 times)

Offline Formigal

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DC 41 Motor replacement
« on: May 08, 2016, 10:41:52 PM »
We bought our DC 41 on Amazon a couple of years ago, and had it shipped to Portugal where we live.  Dyson have advised that as the unit was purchased in the UK and delivered to Europe, the guarantee is void.   (So much for the EU)

Yesterday the main ball motor was very noisy, possibly brushes arcing, so today I have read all available Dyson posts and have stripped the unit down in order to remove the motor and see what the damage is.
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This is the motor side.  There are no visible screws or retainers, but the motor does not slide out easily and I am reluctant to apply excessive force to remove it.
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This is the motor bucket side and I believe I have removed everything that could retain the motor.
Does anyone have any tips or tricks for extracting the motor from the bucket?

I also noticed that as shown on other posts, the yoke which supports the brush head has cracks on the side mounting plate, so I will be replacing this as well during the rebuild.
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Whilst I appreciate the comments of the moderator that to remould this part would be a huge cost to Dyson it is a shame that considering how well built the rest of the machine is that this part suffers from a design flaw.

Online Parwaz7862

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Re: DC 41 Motor replacement
« Reply #1 on: May 09, 2016, 02:08:11 AM »
Hi
the motor just lifts out, it may seem like it's clipped in or something similar but it's only held on by a rubber gasket and the motor housing so it just lifts out, no special technique required ;)
DC14s are tanks, just need a slightly longer motor life. Do plastic parts often break on DC14s? Nope. DC41- Sexy looking futuristic and powerful machine. Just needs a better designed cleaner head wheel and cyclone clip along with a dense metal rod in the chassis.

Offline Formigal

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Re: DC 41 Motor replacement
« Reply #2 on: May 09, 2016, 02:42:30 PM »
Thank you. I will try again.

Online MVacs

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Re: DC 41 Motor replacement
« Reply #3 on: May 09, 2016, 05:46:44 PM »
You actually twist it anti clockwise a little and tilt it to get it out. Getting the new one back in is harder.

Offline Formigal

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Re: DC 41 Motor replacement
« Reply #4 on: May 19, 2016, 01:36:57 AM »
The replacement motor arrived: Thank you Manchester Vacs - prompt service.  However there is a difference in the way that the motor leads connect.
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The old motor has loose leads which terminate in a plug connector.  The new motor has  lugs which protrude from the plastic support bracket.  Clearly I can snip off the old plugs from the motor bucket wires and replace with lug connectors, but there seems to be a good reason why the old plug connector method was used.

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When I tested the fit of the new motor, the lug connectors fouled the motor bucket casing and I could feel that it would take considerable force to make it sit down in the bucket.  I compared this with the old motor and found that the motor slipped much further down in the bucket before I met any resistance.

[ Specified attachment is not available ]

My question is; Can I cut the black wires off the lugs, fit the old connectors (or similar to them) and then cut or file off the protruding plastic lug supports so that the configuration better matches that of the old motor.
Your advice is most appreciated.

Offline Formigal

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Re: DC 41 Motor replacement
« Reply #5 on: May 19, 2016, 01:41:51 AM »
Attachments to my previous post slipped out of order. 
First attachment should be

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Second attachment is actually the first in my posting and
The third attachment is actually the second shown in my posting and should be inserted where it reads (Attachment not available)

Online MVacs

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Re: DC 41 Motor replacement
« Reply #6 on: May 19, 2016, 11:57:50 AM »
I think it mentions it on the motor listing: You swap over the thermal cut out from your old motor to the new.

Offline Formigal

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Re: DC 41 Motor replacement
« Reply #7 on: May 19, 2016, 11:20:15 PM »
Thank you, I had read that somewhere, but forgot about it when faced with the two motors.

I have now reassembled the DC41. I was certainly a challenge, but fortunately I have the time and patience to deal with it.  I feel sorry for those who bought a Dyson believing it to be a solid and reliable machine and who are faced with the huge costs of repair for basic components like motors, that should run for years without problems, not to mention pieces of broken plastic such as the yoke, and also I have discovered a broken change over valve linkage. (See attached photos). In the general view, I have highlighted the part with red tape.  In the detailed photo you can see that one of the lugs has broken clean through.  Whilst this does not seem to prevent the linkage from working, I have effected a temporary repair until I receive a replacement part. I drilled a 3mm hole right through the post and its broken half, and reassembled the link in the machine with a 3mm bolt passing through and secured with a retaining washer and nut, which effectively secures the linkage in place.

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Finally I have to say that before I embarked on this project I read extensively through this and other Dyson forums.  The most helpful link I came across is a youtube video of the dismantling and assembly of a DC50 which is very similar to the DC 41. I read how several people after completing the reassembly found that they had parts or screws left over.  I though how STUPID that must be and took great care to place all the screws from the left side into one container and all the scres from the right side into another, and even taped some screws in place or reinserted them as soon as the part was removed if I thought that I might lose track.  As I replaced parts, I kept checking how many screws I had left and verified the number of locations where screws were required.  This photo shows the end of reassembly with the vacuum tested successfully.  I can now claim full membership of the "Stupid Club" as I have three screws left over.

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