Hello. This is my first post on this forum, and it was driven by a failure on my DC25 today.
I went out for the paper this morning, and as soon as I returned home, I immediately smelled an unusual odor. My wife then announce that she thinks the Dyson has an issue...
My first thought was to begin with the cleaner head, and sure enough I found the problem immediately. It appears that the ball bearing on the end of the beater/roller brush had become packed with dirt/hair (we have dogs & cats). This appeared to impeded the bearing from spinning freely. Subsequently, the entire bearing (not just the ID) began to spin in the end cap assembly, which melted/destroyed the plastic.
Now I need to order a replacement end cap and ball bearing.
Frankly, I was disappointed at the lack of solidity of that endcap. It isn't held very securely in place, which seems to be due to the design that allows easy removal for access to the roller brush. Unfortunately, that portion of the vacuum is exposed to repeated impacts as it's being used regularly. This would make even a rugged design difficult to withstand.
I have a machine shop at my disposal, and have half a mind to machine an aluminum replacement part that will provide a more sturdy support. Before I do that, I would like to see if the replacement parts can be easily ordered first. I am a bit apprehensive since I am located in the U.S. at the moment.
If anyone can alleviate my fears, and provide a bit of guidance, that would be wonderful.