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How do I remove a motor from a Dyson DC04? The bottom plastic cover can be removed by unsrewing the tork screws but the cover beneath the filter won't come off

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Re: How do I remove a motor from a Dyson DC04? The bottom...

I can't say exactly how to do this, but when you can't find the screws to take something apart, they are usually hidden by something else. You did good looking under the bottom cover, but what you're looking for is elsewhere. If there is a seam or line around the middle where it looks like two halves fit together and you can't find anymore screws, use a flat blade screwdriver and GENTLY start to pry them apart to see if they start to separate. If it doesn't give easily, don't force it. Many times a cover will snap into place and then is held secure by screws.

Good luck, and please remember to rate this. I want to know if this helps at all.

Thanks, and good luck!

Posted on Feb 04, 2008

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Dyson sell a bent screwdriver.....
.... to make it easier to remove the switch cover:
I have used an ordinary screwdriver pushed into the tiny gap between the flat side of the switch cover (see picture above) to force the 'tooth' away from its housing, and then pull cover off.
Underneath is a torx-headed screw, which when removed allows withdrawal of the switch assembly.

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Dyson DC04 is making a grinding sound & smells of burning. Hi. I have been told that the above is due to the carbon motor brushes burning out. The brush at the bottom still turns ok. I have bought 2...

Hi there SmartAlec from here, this is not a repair for the faint hearted. First i am assuming you are not using a clutch model - with a selector for carpet/hard floor on the side. If you do have that model i can give you extra instruction. First you will ned a torx driver (like a phillips head but with a star) size 15. Remove the clear bin, the hose that runs up the back of the vacuum and the filter cover and filter. Also remove the inspection tube at back of machine and anything else that pops off easily.
Next turn the dyson dc04 vacuum cleaner upside down and remove the base plate this is done with a large flatblade screwdriver.
The next step is the brush - you should be able to access the drive shaft and pull the belt off which will free the roller.
Unclip the small hose which goes from soleplate to the back of vacuum and remove the soleplate itself you will need to apply very firm pressure and only pull each side out a little way because if you go too far you will crack the guide.
Next is to remove the housing that holds the whole brush assembly. You will see on either side of the vacuum 1 plastic washer (like a circle with a bit taken out) which has to be removed. Once both are off you can gently slip off the body over the shaft that the washers held the body on to. This removes the the body part that moves up and down to adjust your dyson to different height carpets.
Now you should have basically a "nude' dyson
Next step is to remove the 8 torx screws that are spaced around the motor housing. The plastic outer will now come away revealing the last bit of motor casing.
There is a cover plate that is held in by 4 lugs that can be gently pried back with a small screwdriver and the lid will come off like a tupperware container.
From here your on the home straight.
The motor now needs to be pushed out of its little case. The large rubber gasket will make this quite hard as it it designed to hold the motor in but with a fair bit of pressure it will slide out.
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Reversing the process is as simple (after youve done a few) as reversing the instructions and keep in your mind if you have to apply a lot of force it is likely that something is not lined up properly.
Hope this helps. if you need more tips hit me on the website

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