Replacing the Motor (Models with Brush Control)

PLEASE NOTE: If your are in anyway unsure of any of the steps listed below. Please consult a qualified electrician and always disconnect the Dyson from the mains before commencing work.

1. Start by removing the cyclone/bin assembly from the main body.

 

2. Remove the post motor filter cover by using a two pence piece to twist the cover off.

 

3. lay your Dyson onto it's back and, using a two pence piece, turn each of the three soleplate fasteners a quarter of a turn in an anti-clockwise direction.

 

4. Remove the soleplate by twisting either side of the centre plastic screw.

 

5. Place the DC04 Brush Roll Removal Tool (Designed by and sold exclusively through www.sparesaver.com) over the brush roll at the belt end.

 

6. Using the belt hook, pull the belt onto the bottom holding pin of the DC04 Brush Roll Removal Tool. Then hook the belt onto the top pin.

 

7. Carefully pull the brush roll out of the brush holder. (You may find it easier to remove the brush roll's black end cap before pulling it through the belt opening.)

 

8. Remove the internal hose by firstly pulling it from the main body.

 

9. Then pull the other end off the brush holder.

 

10. Remove the brush holder by grasping the end firmly and rocking it backwards and forwards whilst pulling it away from the cleaner head.

 

11. Then remove the brush holder from the other end using the same method.

 

12. Remove the U-bend.

 

13. Using a Torx T15 screwdriver remove the 3 screws holding the clutch cover in place.

 

14. Using a large flat screwdriver remove the belt from the motor shaft.

 

15. Remove the first cleaner head circlip.

 

16. Then remove the second circlip from the other side.

 

17. Remove the cleaner head by holding both sides firmly and pulling one end outwards to free it from the main body. Then do the same to free the otherside.

 

18. Remove the bearing clip by very carefully, unhooking it and gently prising it free.

 

19. Then remove the bearing clip from the other side.

 

20. Using a Torx T15 screwdriver. Remove the 8 screws that hold the upper motor cover onto the main body.

21. Carefully pull the upper motor cover and motor housing away from the main body.

 

22. Carefully spread the sides of the upper motor cover and pull it away from the motor housing.

 

23. Remove the fancase pipe.

 

24. Gently prise the motor retaining ring away from the motor housing.

 

25. Remove the motor retaining ring completely

 

26. Grasp the fancase mount firmly and pull the motor out of the motor housing.

 

27. Remove the motor completely out of the motor housing and note the correct connections of the wires. (Red to Brown (live) & Black to Blue(neutral))

 

28. Before fitting the new motor ensure that the rubber motor bearing mount and rubber fancase seal from the old motor are correctly fitted to the new one. Ensure that the holes in the motor bearing mount (red arrows). Line up with the pegs in the motor housing (blue arrows).

Reassembly is a simple reversal of the steps listed above.