The World's #1 Vacuum Cleaner Advice, Repair, Discussion & Information Forum

Author Topic: Dyson DC40 Mk1 (Pre EU) - Stripdown and Refurbishment  (Read 771 times)

Online beko1987

  • Member
  • Posts: 3637
  • Country: gb
  • Gender: Male
  • Let's take it apart!
    • My blog
Dyson DC40 Mk1 (Pre EU) - Stripdown and Refurbishment
« on: July 21, 2017, 01:00:56 AM »
The other month, I was lucky enough to be given a DC40 Mk1 from a colleague at work.

<a href="https://www.youtube.com/watch?v=rVJEQcDx8cY" target="_blank">https://www.youtube.com/watch?v=rVJEQcDx8cY</a>

So, naturally, it needed to be stripped down and refurbished!

Before that, however, I needed to get it working. The changeover valve was jammed up with a long cocktail stick. I neglected to take photos of it in place, but I pulled it out, and the changeover valve worked once more!

ila_rendered

Next was the clogged brushroll housing (a common issue, one that I have fixed a few times before on other peoples machines!

ila_rendered

The suction inlet is so narrow it blocks up very easily, and build up some more until it clogs fully

ila_rendered

It worked well after this. I even got the box from their new cleaner, a DC40 Mk2!



However, there was a bigger issue with the machine



The yolk pivot stop was snapped off, so the machine fell over very easily, especially when using the tools!

ila_rendered

Luckily, it was still under warranty with Dyson! So I told a white fib which results in it being registered to my Mum, who had bought it brand new in 2013 but lost all the paperwork, but really loves her Dyson, uses it every day etc, and a nice but apparently rushed man came round and replaced it within 30 minutes!



I then meant to use it for my vacuum for May, but TBH forgot it was at Mums and only used it for 2 weeks... Mum used it quite alot though, she almost liked it

https://www.youtube.com/watch?v=5IF8WGDtXUc&t=33s

https://www.youtube.com/watch?v=SHS6y-n7JT8&t=201s

Fun now over, it's time to get to work!

Cyclone off

ila_rendered

Drop the cable

ila_rendered
Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Online beko1987

  • Member
  • Posts: 3637
  • Country: gb
  • Gender: Male
  • Let's take it apart!
    • My blog
Re: Dyson DC40 Mk1 (Pre EU) - Stripdown and Refurbishment
« Reply #1 on: July 21, 2017, 01:04:46 AM »
With that off the horrible wand can come off

ila_rendered

I don't know if the red part comes off, I doubt it though. The tool latch pops out though, along with it's little spring

ila_rendered

The top cord hook is removed by popping the screw cover off

ila_rendered

and removing the screw and then spring underneath

ila_rendered

Hose now, it's removed by releasing the red catch then pulling upwards

ila_rendered

Different angle showing the latch part of the red bit

ila_rendered

And off, into the washing machine it went!

ila_rendered

Tools now!

ila_rendered

All you can really do is pull the dusting brush off the crevice tool!

ila_rendered
Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Online beko1987

  • Member
  • Posts: 3637
  • Country: gb
  • Gender: Male
  • Let's take it apart!
    • My blog
Re: Dyson DC40 Mk1 (Pre EU) - Stripdown and Refurbishment
« Reply #2 on: July 21, 2017, 01:08:42 AM »
I did not know this until this point, but pushing on this catch here

ila_rendered

releases the top handle!

ila_rendered

George from here then pointed out on facebook that how did I think it went in a box shorter than it?... :underchair:

The cap and cover can be removed by lifting this tab up under here

ila_rendered

Then lifting it off

ila_rendered

The wand cap snaps off with a little twist

ila_rendered

It's easier to photograph now!



Behind the switches are 4 screws, which need to be removed



Then 2 plastic tabs which need to be gently released

ila_rendered

The switch housing can then be removed

ila_rendered
Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Online beko1987

  • Member
  • Posts: 3637
  • Country: gb
  • Gender: Male
  • Let's take it apart!
    • My blog
Re: Dyson DC40 Mk1 (Pre EU) - Stripdown and Refurbishment
« Reply #3 on: July 21, 2017, 01:13:51 AM »
We get asked about how this all fits together alot in the DC24 and 25 room, as if you yank it too hard it all falls out, so I made sure I took a really clear image of this bit!



The switch covers themselves just lift out

ila_rendered

And the springs and white arm lift out

I got this part to move

ila_rendered

But not come out so I left it be

Now we can remove the switches themselves

ila_rendered

Lift the switches out, and disconnect the middle red brushroll reset wire

ila_rendered

Then unplug everything else, the blue wire being connected up under this junction box.

ila_rendered

Around the back, the lower cord hook lifts off the hose entry point

ila_rendered

And the spinal cord can be withdrawn from the top of the cleaner

ila_rendered

I did try to remove this seal, but it's glued on good and proper, so left it.

ila_rendered
Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Online beko1987

  • Member
  • Posts: 3637
  • Country: gb
  • Gender: Male
  • Let's take it apart!
    • My blog
Re: Dyson DC40 Mk1 (Pre EU) - Stripdown and Refurbishment
« Reply #4 on: July 21, 2017, 01:17:30 AM »
The tool holder is removed by lifting a little tab and sliding it upwards

ila_rendered

Time to remove the cleanerhead now

ila_rendered

Removing the red clip allows the cleanerhead to fall off onto your foot  >:(

ila_rendered

Remove the post motor filter

ila_rendered

And then move onto the other side. The outer cover twists off half a turn (and you can tell the Dyson man has been here before...)

ila_rendered

Revealing this damaged black 'nut'

ila_rendered

Which can be unscrewed with a pair of long nosed pliers

ila_rendered

Voila!

ila_rendered

It now won't stand up easily though...

ila_rendered
Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Online beko1987

  • Member
  • Posts: 3637
  • Country: gb
  • Gender: Male
  • Let's take it apart!
    • My blog
Re: Dyson DC40 Mk1 (Pre EU) - Stripdown and Refurbishment
« Reply #5 on: July 21, 2017, 01:34:36 AM »
These two metal washers sit under the non filter side of the ball on the screw thread

ila_rendered

I laid the machine down now

ila_rendered

And reclined it back, which caused this piece to fall out

ila_rendered

Which was a pain as I had no idea where it came from or how it fitted on. We'll worry about that later...

I took the post filter backplate off now

ila_rendered

Then undid these two screws here

ila_rendered

And these 3 here, which are only visible if the housing is rotated just so

ila_rendered

This allows the yolk housing to be removed

ila_rendered

But wait, the yolk wiring loom (which is where that random part came from) is still connected

ila_rendered

The wiring plug lifts out of its place

ila_rendered

and it is apart!
Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Online beko1987

  • Member
  • Posts: 3637
  • Country: gb
  • Gender: Male
  • Let's take it apart!
    • My blog
Re: Dyson DC40 Mk1 (Pre EU) - Stripdown and Refurbishment
« Reply #6 on: July 21, 2017, 01:39:49 AM »
The post filter side of the assembly has this black plastic cage over the rod, held in with a screw

ila_rendered

Once removed it reveals 2 more metal washers

ila_rendered

This is the brand new yolk pivot stop bar and it's spring

ila_rendered

And this shows the position of the clear cog part before we remove it

ila_rendered

ila_rendered

Like so!

The internal hose that sits in the yolk pops out via a securing tab

ila_rendered

These 2 metal roller wheels aid the 2 ball halves to spin smoothly

ila_rendered

And the yolk is stripped down. Back to the main machine!

ila_rendered

Already removed by this picture, the top vanity cover slides forward and off, revealing the PCB cover

ila_rendered
Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Online beko1987

  • Member
  • Posts: 3637
  • Country: gb
  • Gender: Male
  • Let's take it apart!
    • My blog
Re: Dyson DC40 Mk1 (Pre EU) - Stripdown and Refurbishment
« Reply #7 on: July 21, 2017, 01:43:53 AM »
Which itself is held on with some screws

ila_rendered

ila_rendered

Revealing the quite tight PCB

ila_rendered

First out is the cleanerhead loom, which plugs in bottom left

ila_rendered

The other end of the loom opens up and allows the individual wires to be removed

ila_rendered

Back to the PCB now and I just started pulling wires...

ila_rendered

This right angled brown first

ila_rendered

Then this straight brown which connected to the black wire to the motor

ila_rendered

Then the blue wire which connected to the double white

ila_rendered

Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Online beko1987

  • Member
  • Posts: 3637
  • Country: gb
  • Gender: Male
  • Let's take it apart!
    • My blog
Re: Dyson DC40 Mk1 (Pre EU) - Stripdown and Refurbishment
« Reply #8 on: July 21, 2017, 01:49:38 AM »
At this stage I lifted the PCB out, one last white wire remaining

ila_rendered

One PCB

ila_rendered

Some screws later and the PCB cage, which also turns out to be the entire siction duct from the motor to the bottom of the cyclone (almost exactly the same setup as the DC15, with the PCB being cooled with the main airflow path of the machine. Great when it's running cool, not so great when it clogs up and heats up...)

ila_rendered

ila_rendered

The cyclone seal can be lifted off at this point

ila_rendered

Nestled within the PCB housing is the release valve. A standard DC24 type affair, a slight turn to unlock the cap and out it comes

ila_rendered

This chap here is the Brushroll switch.

ila_rendered

looks identical to a DC25 one...

It lifts out, along with the white lever

ila_rendered

Which has a spring behind it that looks like it does above!

Next up is the spring that attaches to the wheels, and makes them flick up and down with the reclining mechanism

ila_rendered
Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Online beko1987

  • Member
  • Posts: 3637
  • Country: gb
  • Gender: Male
  • Let's take it apart!
    • My blog
Re: Dyson DC40 Mk1 (Pre EU) - Stripdown and Refurbishment
« Reply #9 on: July 21, 2017, 01:54:09 AM »
With this removed, the wheels lift away from the main chassis too

ila_rendered

The airpath rodding cover pops off now

ila_rendered

Then 5 screws later the motor comes out!

ila_rendered

As does the spinal cord from the base of the chassis

ila_rendered

Leaving the motor for now, the changeover valve is next, and this spring needs to be removed, and the grey part lifting off

ila_rendered

This black peice with the single screw clamps the changeover valve hose in place, and can be removed

ila_rendered

On the other side, these two screws hold the assembly from this side

ila_rendered

Then the other side is held in with this screw

ila_rendered

The whole assembly lifts out now

ila_rendered
Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Online beko1987

  • Member
  • Posts: 3637
  • Country: gb
  • Gender: Male
  • Let's take it apart!
    • My blog
Re: Dyson DC40 Mk1 (Pre EU) - Stripdown and Refurbishment
« Reply #10 on: July 21, 2017, 01:59:58 AM »
Remove the spring from the holding bracket

ila_rendered

And pull the other bracket out from the end of the hose. I took the seal off too

ila_rendered

That is the chassis fully stripped! Onto the motor now

ila_rendered

Remove the screws holding the top cover down

ila_rendered

The fancase seal lifts out of this cover

ila_rendered

Then the motor lifts out of the housing, youll need to pull the sealing grommit out of the housing too with its wires. Except it doesn't... It won't come out AT ALL, so a carbon brush, the one you can get to with the motor fitted has to be removed to get the motor out of the housing!

ila_rendered

Motor ID. DC25?

ila_rendered

The top mount sits in the top of the housing

ila_rendered

This black sliding part (I think it has something to do with the wheels) is unscrewed from the motor housing

ila_rendered
Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Online beko1987

  • Member
  • Posts: 3637
  • Country: gb
  • Gender: Male
  • Let's take it apart!
    • My blog
Re: Dyson DC40 Mk1 (Pre EU) - Stripdown and Refurbishment
« Reply #11 on: July 21, 2017, 02:04:55 AM »
Revealing a locking latch and a ruddy strong spring

ila_rendered

Which just lift out

ila_rendered

This white lever (the purpose of which I have forgotten...) is removed with one screw, noting the blurry orientation of the spring...

ila_rendered

Naked

ila_rendered

We've filled up a flipping screw card already!



But we aren't done yet!

ila_rendered

Time for the cleanerhead, I hear you cheer!

ila_rendered

(What's that? No one's cheering? Well tough!) I cracked out some sugar and tea, and carried on

ila_rendered

Baseplate off

ila_rendered

Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Online beko1987

  • Member
  • Posts: 3637
  • Country: gb
  • Gender: Male
  • Let's take it apart!
    • My blog
Re: Dyson DC40 Mk1 (Pre EU) - Stripdown and Refurbishment
« Reply #12 on: July 21, 2017, 02:10:03 AM »
I did look into separating the floating baseplate, but even with the tabs unlatched, the rubber glued the 2 parts together, and if I tore that it would be game over, so I left it whole

ila_rendered

Brushrolls removed with a half twist and a pull and 2 screws either end... Cross head too, the only ones on the whole damn machine!

ila_rendered

The end caps (which ARE handed by the way) can be removed by undoing the centre screw

ila_rendered

and pull off, revealing the delightful underneath!

ila_rendered

Onto the motor now, and not really knowing where to start I just undid all the screws that looked like they held the motor housing to the cleanerhead

ila_rendered

This trim piece came off too

ila_rendered

As did the cover

ila_rendered

Dr Johnson, I presume?

ila_rendered

In amongst removing all the screws this sealing/deflector plate lifts out

ila_rendered
Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Online beko1987

  • Member
  • Posts: 3637
  • Country: gb
  • Gender: Male
  • Let's take it apart!
    • My blog
Re: Dyson DC40 Mk1 (Pre EU) - Stripdown and Refurbishment
« Reply #13 on: July 21, 2017, 02:14:51 AM »
I unplugged the wires from the motor, and lifted the whole housing out from the cleanerhead

ila_rendered

The small loom that takes the power from the cleanerhead join to the motor lifts out of it's circular groove

ila_rendered

and the plug can be removed from the mounting piece. But the plugs don't come apart any further

ila_rendered

Just as I was about to give up and jsut wash the wires with the head, I found the white plug just about squeezes through the hole, so can be removed

ila_rendered

The front bumper snaps off

ila_rendered

To remove the motor from its mounting plate, the brushroll cogs have to be unscrewed from the gearbox

ila_rendered

Which then allows the unit to be withdrawn. Some more screws on the casing

ila_rendered

Split it open even further

ila_rendered

The cog part pulls carefully out of the outer housing, bringing the bearing with it

ila_rendered
Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Online beko1987

  • Member
  • Posts: 3637
  • Country: gb
  • Gender: Male
  • Let's take it apart!
    • My blog
Re: Dyson DC40 Mk1 (Pre EU) - Stripdown and Refurbishment
« Reply #14 on: July 21, 2017, 02:18:13 AM »
Belt ID, although I can't imagine it'll ever break or get damaged

ila_rendered

Finally the motor pops out of the housing in the same way a DC24/5 one does from it's housing!

ila_rendered

I de-fluffed it

ila_rendered

This piece does come out, it just sits here like this, the internal spring sits over it. Pic for orientation id

ila_rendered

Cyclone next!



Bin off

ila_rendered

Bottom flap off

ila_rendered

Red release rod popped out of the channels on the side of the bin

ila_rendered

And the seals pulled from the bottom flap

ila_rendered
Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Dyson Spare Parts


 

 

Dyson Spare Parts

 

 

Sebo Vacuum Cleaners

 

 

Buy a Dyson DC04 Wand Handle

 

 

 

 

The Dyson Medic Blog

Dyson Spares, Parts, Advice   Follow us on Twitter

Manchester Vacson Google+

Manchester Vacs on Instagram