how do i get at the power cable/switch on a dyson dc04 to repair ir

dave smith, September 2003

This is what I did to replace the power lead on my DC04:

I got a terminal driver and slid it down the side of the button-switch where the small release catch hole is (buttons nearest point to the main handle). Once I was down about 20mm I opened up the gap a little by leavering the terminal driver and I could see the release catch (part of the button). I then moved the terminal driver to the side of it, got under it and gently levered the release catch out of its moulded track. The button then slides out, but may need a little gently levering. Once you have the button off you'll need a torx screwdriver (looks like a star pattern at the end) to release the switch housing. It might also need a little gently levering once you've removed the torx screw to get it out.

Once you've got the button out, you'll see the brass connectors incased in plastic. I used the existing connectors by leaving about 4 inches of the old cable still connected and used connector-blocks to join the new power lead to them. There is enough room in the switch housing to fit two small connector blocks. The flex grip keeps the lead secure, so be sure to put it in properly (don't forget to put the flex protector back on before connecting up the new cable). Put the switch housing back in, screw in the torx screw and pop the button back in, ensuring the release catch is back in its track properly. Job done!

Johnny, March 2006

Here is a reliable method of removing the yellow switch cover without breaking anything.

1. Get hold of a 120mm length of 1.6mm diameter sprung steel wire. I got some from a model shop.

2. Make a bend 20mm from the end at about 45 degrees.

3. Make another bend at the same end 6mm from the end by a further 25 degrees.

4. Use a good light source so that you can clearly see down the side of the switch cover.

5. Use a small terminal screwdriver to gently open up the gap between the flat side of the switch cover and the grey surround.

6. Insert the 'release tool' that you have made sideways into the gap.

7. Rotate the tool so that the bent end pushes against the barb on the switch cover. The 'shaft' of the tool should locate in the small notch in the grey surround.

8. You should be able to see the barb getting pushed in. You can continue to use your terminal screwdriver to help hold the gap open so that you can see what is going on.

9. Using a narrow wood chisel between the switch cover and the surround at the front of the Dyson, carefully lever the cover upwards. Wear some protective gloves if you think that you may slip with the chisel!

10. As soon as the barb has passed the lower edge of the surround you can remove the release tool and the cover will come out easily.

11. You now have access to the switch and cables.

Kevin, July 2005

As above to remove the yellow switch insert your feeler gague or implement about 0.5mm thick ,between the flat of the yellow switch and the grey plastic immeditaly next to it , the hook is about 30mm down from the top of the switch ,if you lever slightly towards the outside of the hoover to push the yellow switch into its own body (imagine a cylindrical can with a hook pointing to the outer side which exceedes the(circumferance ) push this in slightly and wiggle the switch till it comes out . after that its a matter of joining the broken cable ,as was in my case of the DC04

jamie jrobertson1012000@yahoo.co.uk, January 2005

To add to Nick's answer - which was a real help to me - I hope he doesn't mind me using his text and adding my small but valuable comment:

At first there doesn't seem to be any way into the switch, but… it does dismantle by first removing the yellow button. It pulls up - but there is a barb on the side of the button nearest the main housing (flatter side of the button) which needs to be depressed first. If you can get a thin piece of plastic to slide down the side of the button, you should be able to pull the button up with something like a mole wrench.

Paul's added help: Instead of plastic, use a thick-ish feeler gauge to slide down, but do it between the grey handle and the grey switch housing - I found (to my cost) that if you push it down alongside the yellow button, the tab or barb on the button will break off. You can depress the tab inwards towards the switch, and using aforementioned mole wrench, gently wiggle the yellow button off. Hope that little tip helps.

Once inside, there is a star shaped screw (need a special bit) which undoes to release the switch housing. Make a sketch of the wiring so you can put it back the same way!

Lever out the brown switch. Pull the connectors apart and resolder the mains lead. Reassemble (as per the sketch!).

Its well worth making sure that the rubber cable grommet thingy goes back in place. I used some silicon sealer to 'glue' it back in place. This should help stop it breaking again.

Hope this help - good luck!

Paul Baldwin, April 2004

Go hear and take a look it may help
http://www.moseng.fsnet.co.uk/personal/MyDyson.html

Stan the Man, January 2004

At first there doesn't seem to be any way into the switch, but… it does dismantle by first removing the yellow button. It pulls up - but there is a barb on the side of the button nearest the main housing (flatter side of the button) which needs to be depressed first. If you can get a thin piece of plastic to slide down the side of the button, you should be able to pull the button up with something like a mole wrench.

Once inside, there is a star shaped screw (need a special bit) which undoes to release the switch housing. Make a sketch of the wiring so you can put it back the same way!

Lever out the brown switch. Pull the connectors apart and resolder the mains lead. Reassemble (as per the sketch!).

Its well worth making sure that the rubber cable grommet thingy goes back in place. I used some silicon sealer to 'glue' it back in place. This should help stop it breaking again.

Hope this help - good luck!

Nick Williams, October 2003