Dyson DC02 Cable Repair/Replacement
This guide will show you how to change the cable rewind on the Dyson DC02 cylinder vacuum cleaner.
Although it is possible to change just the cable, and reuse the old cable reel, there is a real element of danger with the rewind spring. If it springs out it can cause serious injury so our advice is don't dismantle the cable reel/rewind mechanism. Replacement cable reels are now totally obsolete, so if yours has broken, you need to source a good used one now.
As with all repairs, please double check the appliance is unplugged from the mains.
Tools Needed and Other Information
A T15 screwdriver and a couple of flat blade screwdrivers for leverage, a pair of needle nosed pliers would also help. If you need a T15 screwdriver you can buy an inexpensive, top quality one >>here<<.
Note: This vacuum is very old now, and the plastic can sometimes be brittle, so please take extra care when removing trims.
The first step is to remove the suction hose, this is done by squeezing the two side buttons like so.
Pull the hose out.
Now remove the two filters, these can vary from model to model but these here are the washable type. This filter slides up.
And this filter pulls out.
Unlatch the tool storage and remove the tools.
The tool storage door now has to be unclipped.
It is hinged at either side and it needs to be gently prised away.
Here is the other side.
Very gently prise the door away from the body at both ends; a flat blade screwdriver will help.
Removed - and in one piece!
Now, the top of the body has to be removed; this is a similar process to the previous step.
Gently push the lugs inwards at both sides.
Remove the top.
You should now have something resembling this.
Turn the machine over and it's now time to remove the five Torx screws (arrowed).
Unscrew the screws.
With the screws removed, the lower casing will now start to come away.
When pulling the lower casing away, the plasic wheels will need pulling to allow it to move over the casing. This can be a bit tricky!
The lower casing is now off the body.
The next step is to push the plug out of the casing.
This is the easiest way. Just turn the plug like this.
And slide it out.
Here it is removed.
The next step is disconnecting these two wires. I have seen various wiring set ups in the DC02, but they are all similar. The model I am using here has a wire to the switch and a wire to the motor. Yours may be slightly different; but its these two wires that will need disconnecting.
Please ensure you know what colour wire went where and disconnect. This is the wire connected to the motor.
And here is the switch wire disconnected.
Pull the wires back and remove the cable reel.
The end of the cable can be secured in this clip built onto the drum if needed.
Now place your new cable reel in the machine, and attach the two wires back in the correct places.
(The new cable reel - if you are lucky enough to find one - may be secured with a metal or plastic clip to prevent it unwinding in transit. This should be removed first.)
Ensure the wires are seated in these recesses correctly.
Also make sure the new cable reel lugs are sat in the recesses.
Push the plug back through the lower casing like this.
Refit the lower casing. Once more, the large plastic wheels will need pulling apart to allow it to clear the case.
There is a risk of the cable getting trapped, so check this part.
Make sure there are no gaps here on both sides.
And make sure there are no gaps on the back also.
Refit the five T15 Torx screws.
The next step is to pull out the cable and test the rewind unit with this button.
Gently refit the top of the vacuum cleaner.
And gently refit the tool door.
Take your time........
Replace the tools and close the door.
Refit the rear filter.
And now the top filter.
Refit the dust bin and close the unit.
Refit the suction hose. Test themachine, and if you did it all correctly, everything should be fine now.
The DC02 is now a very old machine and the plastic trim can get brittle so please take care.
Don't forget to get your vacuum cleaner PAT tested after any repair