Dyson DC07 Clutch replacement
Remember to have the appliance unplugged before attempting this repair.
Tools needed:
Large flatblade screwdriver
T15 torx screwdriver (buy a cheap, top quality one here)
Needle nose pliers (possibly)
Possible symptoms
The things to look out for are:
Very violent cracking noise when the clutch is engaged.
Belts can break but this is very rare with the clutch control models
Over time the belts can stretch and the vacuum will lose performance changing the clutch may help this.
Please read first.
This repair was on a scrap DC07 model without a motor. I have tried to accomodate this as best i can in the guide.
This repair is almost identical to the procedure in repairing a DC04 with a clutch control so until i do a guide for a DC04 this one should help.
The repair may be quite tricky in parts but not rushing and patience will get it done with the minimum amount of fuss.
The clutch works in the following way.
In the Auto postition the brushbar will rotate when the vacuum is reclined it will not rotate when in the upright posotion.
In the Off position the brushbar will remain off whever the vacuum is reclined or in the upright position.
The idea is for hard floors to be vacuumed without the brushbar rotating.
Where to buy spare parts
Genuine dyson clutch can be bought here
First job is remove the bin.
The clutch mechanism is behind this knob and it controls the brushbar turning it on and off
I removed the rear hose to allow for better flexability when moving the vacuum around, this is not important to the repair but it makes it a lot easier.
The button has to be pushed in here
And now the hose slides up and off the vacuum
Lay the vacuum on its back and turn the three soleplate retainers (arrowed) they turn a quarter turn
Here is one close up
The soleplate has now been removed exposing the brushbar and belt
Pull the brushbar out of the soleplate on the side away from the belt end
Pull the end capoff the brushbar, it may come with the shaft as well but this isnt important
At the other side of the brush bar place a screwdriver shaft under the brush bar and gently pull up the brushbar out of the soleplate
Either pull the end cap off the brushbar or slide it out with the shaft it doesnt matter which way it comes out.
The shaft and end caps have now been removed from the brushbar
Now grab the brushbar firmly and pull it up and out of the belt, please take care not to break the plastic guides that sit either side of the belt. Take your time and use a pull up and pull along method
Like this
Its nearly out
The brushbar has now been removed
Now place the vaccum on its side and pull the the sole plate off by pulling at either side
It unclips away from the footplate and a gentle rocking motion may help to get it out
And here is the other side
As this photo shows the hose that now needs unclipping
Pull the hose away form the vacuum
Your vacuum should now resemble something like this
Next job is to unclip the u-tube at the rear of the vacuum
Now we can see the cover of the clutch
The cover is secured by three T15 screws. These two are obvious (arrowed)
But the third is hidden and is only reached through this hole in the vacuum frame
Slot a T15 screwdriver into the hole
The screwdriver can now reach the screw
Red circle shows where the screw is hiding.
Remove the other two screws
With the screws all removed grip the clutch cover like this
Slide the cover down towards yourself
And slide it along and out
This is the clutch cover
Now unhook this thinner belt off the motor shaft
( I am pretending because as a said earlier the vacuum i was using had no motor!)
Next job is to remove these two retainers
A screwdriver will help
And remove the clip
There are two of these to remove
Now make sure the vacuum footplate is fully reclined
We are now going to remove the footplate off the body of the vacuum
It is held in place in the two position where the retainer rings we removed earlier where.
Gently pull the plastic at either side as shown in the photo
Here is the other side
Gently does it!
Take your time
And its off!
The plastic is stronger than you might think i have done hundreds of these and havent snapped one yet!
We are now going to pull the knob off the clutch
Here is the knob it is latched onto the shaft in two places, removing it requires prising it off alternating between both sides if necessary
Insert a flat screwdriver blade at this position between the knob cover and the clutch and gently prise the knob away(on some models its the black dot or whatever indicates the clutch position)
The knob is latched at the direct opposite side and you will have to prise it gently you may need to keep swapping sides.
Eventually the knob cover will start to come off
Here it is and i have arrowed the two points that latch it to the clutch
Here is the clutch with the knob removed , the latch can be seen
The clutch now needs removing from the baseplate.
A screwdriver inserted here and gently levering may help
This is also a good position to lever up the clutch
And this is a good position as well
Pushing here can help as well
The clutch is now out of the baseplate
Here is the baseplate minus the clutch
New clutch mechanisms will need both the belts stretching a little as they are very tight when new. As i am refitting the old clutch i wont need to do this however the belts on this old clutch are stretched beyond what i would consider acceptable and i would normally refit a new unit.
The new clutch needs to be fitted carefully and i have numbered the three slots it has to slide into
Here are the three slots on the clutch itself
Push the new clutch into place make sure it goes in quite square to the slots and that they dont bend when fitting
Here is the clutch fitted correctly
Check both sides to make sure it is fitted square
Now refit the knob it will usually make a gentle click when done
Now refit the base. gently pulling the two sides apart the same way as when it was removed
Dont forget to refit these two retainer clips
Stretch the thin belt onto the motor shaft ( I am pretending as the machine used had no motor fitted)
Slide the clutch cover back
Now push the cover upwards ensure the belt doesnt get trapped and also that the cover locates correctly
This is important.
The edge of the clutch cover must sit square with no gap. I have circled the location.
If it doesnt remove the cover and try again
When the cover is correctly fitted refit the screws. Dont overtighten
Dont forget the hidden screw
In it goes
Now refit this hose, it just pushes on
Next make sure the belt isnt trapped and can be pulled through the soleplate.
This belt is old and has stretched and a new one will not peek through as much as this.
Now snap the soleplate back in place
Both sides will need doing
Now pull the belt through the hole and slide a screwdriver shaft through it
Needle nosed pliers will help on new belts
Its the same procedure as removal in reverse. First slide the brushbar into belt ,a screwdriver will help here .Please make sure you dont chip or bend the plastic guides either side of the belt
Its fitted and it will be tight!
Opposite side to the belt slide the shaft and cap into the brushroll
Now lever up the belt end of the brushroll and push the cap on.
Ensure that both ends are sat correctly in the soleplate by twisting them unti they sit like this
Make sure they are correctly sat, if not the solplate wont close properly.
Also rock the brushbar and make sure the belt isnt trapped.
Refit and rescrew the soleplate and again rock the brush bar to ensure that it hasnt been trapped.
If you removed the rear hose it needs refitting make sure it has located in its slots at both sides
Refit the u-tube make sure it has located correctly
Done!
Please remember to PAT test your appliance after repair and if in any doubt get a professional to do it.
If you need a replacement clutch please visit my store section for great value parts
If you have any comments on this guide please email me