Loud noise on carpet setting. I've replaced the clutch which comes with 2 new belts and the roller brush.
The answer may depend a bit on the specific model, but it sounds like you're handy enough to have gone in and replaced the clutch. A couple of other thoughts, based in part on doing similar things to my DC07, which I picked up at a flea market and did a refurb on before my wife would let it in the house:
There is the clutch, the roller pin that turns the belt, the belt, the flat spot on the brush where the belt should roll, the brush, and the spots where the brush fits into the ends of the cleaner head.
By 'on carpet setting' I assume that's when you move the clutch to the carpet 'engaged' setting.
When you move the clutch in and out of engagement, is the movement smooth, or are there catches or places where you have to apply a lot of pressure (at least if this is a manual clutch, in some cases it's pushbutton engagement)> If there is resistance or sticky places in engaging/disengaging the clutch, you may need to open things up again and see if the clutch is in correctly.
With the vacuum on, move the vacuum between reclined and all-the-way-up, where it should disengage the brush and switch suction to the handle/auxiliary tool path. Does it turn off the brush and switch suction? If not, then the switch-over may be stuck or sticky and messing with smooth operation.
with vacuum off and clutch disengaged (bare floor mode) can you spin the brush easily with your hand? If you engage the clutch, can you roll the brush with some resistance? Is the resistance steady as you roll the brush through a few revolutions. If not steady, there could be something stuck to a shaft, gear, or belt that you'll only hear when those parts are moving.
A lot of hair or other cruft built up on the roller can make for vibrations, especially if it's stuck to the roller lopsided. Clean it up.
Finally, the brush has non-symmetric fixtures at the end that may not be at all obvious for how they fit into the ends. I know from experience that you can seem to get the brush head all back together when the brush ends aren't in fact seated properly. The system doesn't like this. May take some staring, but open the bottom up (vacuum off, of course), and see if the ends seem to be seated cleanly into complementary shapes.
Good Luck!
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