Dyson DC04 Motor Replacement
Remember to have the appliance unplugged from the mains before attempting this repair.
Possible Symptoms of a Damaged Motor
The things to look out for are:
A strong smell of burning;
The motor may sound laboured;
The motor may make a low popping bubbling noise;
Smoke from motor casing area;
A high-pitched noise may indicate that the motor bearings are worn.
Tools Needed and Other Information
A new motor - but you knew that already didn't you? However, what you probably don't know is that there are two different types of motor fitted to DC04's. You can find a tutorial about that here: Replacing a Dyson DC04 Motor (Ametek or YDK).
You also need a T15 torx screwdriver. If you don't have one - you need one. You can get a new motor and the T15 Torx screwdriver you need >>here<<.
You also need a large flat blade screwdriver for the retaining screws on the soleplate.
The repair detailled on this page was carried out on a lime green and grey machine that has a single drive belt and no clutch. If your machine has a clutch, you will also need a belt removal tool. You can read all about those - how to use one and where to get one from here: How To Use The Dyson Belt Lifter Tool.
Unclip the cyclone unit from the vacuum cleaner body.
Remove the cyclone bin unit from the main body
Unscrew three soleplate retaining screws - a quarter of a turn each with a coin.
Remove the soleplate
Pull the belt off the motor shaft.
Pull the brushbar out.
The small hose here needs to be pulled off.
It comes off quite easily.
Now unclip the brushroll housing away from the head unit of the vacuum. You may need to tilt it each way a little until you find the release position.
Both sides. There is a knack to this you will pick up if you rock it back and forth.
Unclip this inspection tube.
Now unclip these green plastic circlips; a screwdriver helps.
Just ease them off.
Now put the vacuum in this position.
Bend these lugs away from the body on both sides.
A steady hand is needed.
And it comes off completely.
This is what you should be looking at now.
There are eight T15 torx screws to remove. Here's the first one circled in the photograph above.
Two on this side - circled in the photograph above.
Three more at the bottom.
The other two are behind the filter. Unclip the cover.
Pull out this filter.
The top two need unscrewing.
A close up shot.
With the screws out, the motor outer casing will pull apart.
Remove from the body of the vacuum cleaner.
Pull this piece of trim off.
Four lugs on the motor case hold the lid in place.
Unclip the lugs gently and remove the lid.
The motor now needs pushing out of the case; this can require some effort and is best pushed with two thumbs (the camera was in my other hand for this shot).
The motor is now out of its case.
This is the old motor and the top motor mount.
Note the colours and positions of the wires and disconnect the motor.
This is the new motor. Be sure to get an OEM one from a reputable place like Manchester Vacs and avoid cheapo Chinese twenty quid eBay ones that will only last a few weeks - if they work at all!
I have taken the old motor mount and put it on the new motor.
Now remove the lower motor mount from the old motor.
And fit it to the new motor.
Attach the wires (knowing which colour goes to which terminal) and push the new motor back into the case.
There are 2 pins that push into the top mount (arrowed in the photograph).
Put the lid back on.
Refit this piece of trim.
Sit it back into the body as shown.
Refit the top motor case and screw it together.
Refit the base of the vacuum.
Now refit the retaining circlips on both sides.
Refit the small hose.
Clip the brushroll housing back into position.
Push the belt and brushbar back into position.
Refit the belt.
Check that the brushroll moves freely.
Refit the soleplate and coloured screw retainers.
Refit the inspection tube.
Replace the lid and filter.
Refit the cyclone unit and test the machine.
Caution: All work to electrical appliances should only be carried out by competent, qualified people in accordance with their local laws. Faulty electrical appliances can cause serious personal injury and death. Always take the relevant precautions, and if in doubt, consult an experienced engineer.