Sounds ominous. I have repaired a Dyson DC4 today by replacing the motor and pump from yet another unwanted and knackered DC4. The fault with the damaged motor was because the washer between the rotor clamp nut and the delicate aluminium impeller had been incorrectly fitted from new. The washer had been fitted eccentrically thus preventing the nut fully clamping the rotor to the motor shaft. The motor therefore had never carried its full pumping load and had gradually speeded well above its design speed, and had eventually shed one of its commutator wires. Failure symptoms, slow motor speed, little vaccuum, hot electrics smell and a loud growl noise. I suspect there must be many more such faulty machines around and yours is probably one of them. The DC4 I have repaired today is about 2 years old so is out of warranty and I was fortunate to have a similar, but by no means identical, machine to rob. I think you may have a case to approach Dyson and his incredibly successfull machines, none of which I like because of the inadequacy of important structural detail. They are heavy and delicate when subject to reasonable abuse. and I am not surprised to be told the repair costs are high. Gaining access to carry out DIY repairs of these core failures is well beyond most users. Good luck. Tarpiks.
PS. if the motor hasn't failed, it may be possible to remove the motor / pump and adjust and tighten the nut. Good luck again.
Tarpiks, August 2005
