Dyson DC02 Cable repair/replacment
This guide will show you how to change a cable reel on the DC02 cylinder vacuum.
Although it is possible to change just the cable and reuse the old cable reel there is a real element of danger with the rewind spring. If it springs out it can cause real injury and the replacement cost of a reel is now very reasonably priced and makes the repair very straightforward.
As with all repairs please double check the appliance is unplugged from the mains.
Tools needed and other information
T15 screwdriver and a couple of flat blade screwdrivers for leverage, a pair of needle nosed pliers would also help. If you need a T15 screwdriver you can buy a cheap top quality one here
Note: This vacuum is very old now and the plastic can sometimes be brittle so please take extra care when removing trim.
First step is to remove the suction hose, this is done by squeezing the two sides and pulling it out
Pull the hose out
Now remove the two filters, these can vary from model to model but these are the washable type. This filter slides up
And this filter pulls out.
Unlatch the tool storage and remove tools
The tool storage door now has to be unclipped
It is hinged at either side and it needs to be gently prised away
Here is the other side
Very gently prise the door away from the body at both ends a flat blade screwdriver will help
Removed and in one piece!
Now the top of the body has to be removed this is a similar process to the previous step.
Gently push the lugs inwards at both sides
And remove the top
You should now have something resembling this
Turn the machine over and its now time to remove five torx screws (arrowed)
Unscrew the screws
With the screws removed the lower casing will now start to come away.
When pulling the lower casing away the plasic wheels will need pulling to allow it to move over the casing. This can be a bit tricky!
The lower casing is now off the body
The next step is to push the plug out of the casing
This is the easiest way. Just turn the plug like this.
And slide it out
Here it is removed.
Next step is disconnecting these two wires. I have seen various wiring set ups in the DC02 but they are all similar. The model i used had a wire to the switch and a wire to the motor. Yours maybe slightly different but its these two wires that will need disconnecting.
Please ensure you know what colour wire went where and disconnect. This is the wire connected to the motor.
And here is the switch wire after disconnection
Pull wires back and remove cable reel
The end of the cable can be secured in this clip built onto the drum if needed.
Now place you new cable reel in the machine and attach the two wires back in the correct places.
(The new cable reel may be secured with a metal or plastic clip to prevent it unwinding in transit. This should be removed first)
Ensure the wires are seated in these recesses correctly
Also make sure the new cable reel lugs are sat in the recesses.
Push the plug back through the lower casing like this.
Refit the lower casing and again the large plastic wheels will need pulling apart to allow it to move over the case
There is a risk of the cable getting trapped so check this part
Make sure there are no gaps here on both sides
And make sure there are no gaps on the back also
Refit the five screws
Next step is to pull out the cable and test rewing with this button
Gently refit the top of the vacuum
And gently refit the tool door
Take your time
Replace tools and close the door
Refit the rear filter
And the top filter
Refit bin and close
Refit suction hose
Test and everything should be fine
The DC02 is now very old and the plastic trim can get brittle so please take care.
Dont forget to get your vacuum PAT tested after any repair
If you have any comments on this guide please email me