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Author Topic: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!  (Read 6870 times)

Offline beko1987

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Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« on: November 02, 2017, 11:41:35 PM »
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



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:





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

A Dyson DC41 Mk2 Erp for 5!

So on we go!

Cyclone Off



Turn it on it's side, and remove the red clip holding the brushroll housing on

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Drop the cable

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And release the hose

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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!

Offline beko1987

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Re: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« Reply #1 on: November 02, 2017, 11:46:08 PM »
Which was lovely and clean!

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The wand unclips from the hose

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And the tools release button pops off

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As does the cover for the top cord hook screw

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The screw comes out, as does the spring behind it, and the hook itself then falls off the wand

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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

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The rubber cuff pulls off the hose end

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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

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Underneath is the latch that holds it onto the wand

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Offline beko1987

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Re: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« Reply #2 on: November 02, 2017, 11:50:48 PM »
It's operated by this tiny spring

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It just pulls out of the hose cuff

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The main handle is clipped onto the chassis, and released by pushing this black latch in

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The top cover and wand cover are held in with this locking tab

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And pull off when that is released

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Time to remove the tools and tool holder



And pull the combi tool apart

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These 4 screws hold the switch cover in place

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!

Offline beko1987

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Re: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« Reply #3 on: November 02, 2017, 11:57:47 PM »
2 small tabs hold the switch cover on, and once removed it all looks like this

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With the two switches like this

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Pull all the connections apart

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And the mains cable can be removed

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The spinal cord can be pulled out this far for now

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Time to move down now, and remove the post motor filter cover

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The filter had a fair bit of fluff in, but not heavily soiled etc

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It can be removed and cleaned up

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Offline beko1987

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Re: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« Reply #4 on: November 03, 2017, 12:06:17 AM »
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

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The screw underneath can be removed with the same process

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And the shell lifted off

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The top vanity cover unscrews now

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Behind the non filter side sit these two washers, which will fall off if you dont remove them now

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The socket for the brushroll housing can be lifted up now it's not held in with the vanity cover

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But you can't just take the wires out as they run behind this bit of plastic.

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Which you could probably just cut, or you could remove the connectors from the plastic block (they just lift out) and feed them through

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Offline beko1987

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Re: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« Reply #5 on: November 03, 2017, 01:02:29 AM »
With that, the holder is free of wiring

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And we can remove the screws holding the back of the filter housing on

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Next layer now, these screws on one side

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And on the other side, the wheel assembly needs to be rotated to uncover the screws

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The internal hose is held on with a tiny screw

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and once removed the wheel assembly can be lifted off

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On the filter side, we find the same 2 spacer washers, but within a plastic cage



Under the wheel assembly is 4 screws

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Offline beko1987

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Re: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« Reply #6 on: November 03, 2017, 01:10:35 AM »
With those removed the internal hose assembly is seperated from the wheel assembly

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The pivot lock unclips from the internal hose assembly

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Like so

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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!

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This screw holds a plastic cog to the wheel assembly

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These two roller wheels pop out

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Next layer now, the suction duct

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This rear screw is part of it too

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Offline beko1987

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Re: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« Reply #7 on: November 03, 2017, 01:15:03 AM »
Which then lifts off

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The cyclone seal lifts off

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This reveals the PCB, which is held in with 2 small screws

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Remove all the wires and hope this massive capacitor doesn't short out and explode

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Next layer now, the underside of the suction duct!

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Terrible shot but release the wires that run through it as you remove it

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The release valve is hiding in this layer too

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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!

Offline beko1987

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Re: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« Reply #8 on: November 03, 2017, 01:24:47 AM »
The wires sit like so underneath

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The brushroll loom can be removed now

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Aha, we can see the motor housing now

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This is the brushroll switch, that makes the brushroll go on and off when you recline the vac

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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

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WHEEL ASSEMBLY off

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Fancase cover now

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Unlike a DC40, the motor just lifts out!

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And that's it for tonight folks, got to be up early! Moar soon, only another 242 pictures to go...
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!

Offline beko1987

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Re: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« Reply #9 on: November 03, 2017, 08:51:10 PM »
Time for a bit more!

We have the motor out now

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From it's dusty place

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The motor loom pops out of the access hole

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I popped the access cover flap off

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Time to get the changeover valve off now

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First off is a tiny damper valve, just removed from the body of the machine now



Whilst doing this, the bottom cord hook fell off, as it's just held in with the hose, which is now removed

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We are now hampered by the chassis, so let's remove the screws and get that out of the way!

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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!

Offline beko1987

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Re: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« Reply #10 on: November 03, 2017, 08:54:59 PM »
The spinal cord can be removed now as well, as it's held in with the joint

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Back to the valve now, the part that holds the damper valve is held in with this screw

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Then it lifts out

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The damper can be removed with a tiny screw

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The damper itself splits down

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The little hose and pivoting part lifts out now, with a bit of a fiddle with the hose

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Another mounting bracket unscrews

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Inside the motor bucket is a rubber mount

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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!

Offline beko1987

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Re: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« Reply #11 on: November 03, 2017, 08:58:18 PM »
The locking part for the recline mechanism sits under this cover

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It all just lifts out

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That's the main part of the machine done! Time to move on to the cleanerhead!

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Looking lovely

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The baseplate unclips and hinges forward

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Said hinge is held together with some screws

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Which makes it much easier

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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

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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!

Offline beko1987

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Re: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« Reply #12 on: November 03, 2017, 09:01:59 PM »
The red slider pops out

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With a bit of fiddling, the rubber part unclips from the baseplate

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The black slider mount unclips from the rubber part

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As per all of these types of floating baseplate I've seen, the rubber part is jammed up with crud... Deal with that later

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Back to the main head, the front bumper lifts off

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The brushrolls are held in with the end caps being screwed down

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And pull out with the screws removed

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The end caps are screwed into the brushroll

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and prise off easily once the screw is removed

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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!

Offline beko1987

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Re: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« Reply #13 on: November 03, 2017, 09:07:15 PM »
To show the bearing underneath the end cap

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Under the brushroll, there is a deflector plate that slides out

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It's quite clean

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Under the deflector plate are the screws that hold the motor cover on

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To remove the motor parts, the cogs that drive the brushrolls have to be unscrewed and pulled off

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The motor lifts out then, but is hindered by the head loom

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Quick shot of how the wires run before we unplug them

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The motor lifts out

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Typical of the brushroll motors from the DC25 onwards

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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!

Offline beko1987

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Re: Dyson DC41 Mk2 (Erp) - Stripdown and Refurb!
« Reply #14 on: November 03, 2017, 09:11:25 PM »
More filth

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Time to remove this little loom



The wires handily just slip out

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That's the brushroll housing done!

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Onto the drive mechanism now

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Some screws to undo

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Nothing wrong here

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The middle wheel falls out now, held in with the 2 sides of the casing

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The little belt slips off

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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!

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