How do I fix my Dyson DC04 power cord?

1. First things first, To make things easier remove the bin from the front. Use a small flat tip screw driver to gently lever up the on/off button on the side closest to the handle. Be carfull as you may break the little wedge that stops it from coming out when you use it.

2. Under the button you will find a torx screw, If you don't have a torx driver that fits you may be able to use a flat head driver, Undo this screw and the button/cord unit can be then slid up and out.

3. If you can, Take a picture of where the wires go just incase you forget when it's time to put it back together. Unplug all connectors and remove your cable.

4. Cut your cable so you have about an inch of blue and brown cable left on each connector, Next cut away the broken section of cable, Strip away the outer insulation, to leave around 3/4 inch of brown & blue.

5. Strip the insulation of all four ends on brown & blue use one small terminal block, Maybe 3A or 5A for each colour.

6. Put all the wires back as they were, If this does not fit back in the handle remove the insulation from the terminal blocks, Be sure to use insulating tape if you do this.

7. Slide the unit back into the handle, if you have a flat or phillips screw the right size you way want to use this rather than the torx, If you have to do this repair again sometime in the future this will make it easier.

8. If you are unsure of any of these steps I will soon post a video on youtube, search for
"dyson DC04 cable repair".
or go to my page http://www.youtube.com/djdavies83

*All reapirs done at your own risk, The info in this answer is provided only as a guide and the author will not be held liable for any loss, damage or injury however casued*

youtube.com/djdavies83
August 2008

You will have to disassemble the vacuume and get to the point where the cord connects to the common connection and the switch, then unplug them or untwist the wire nut and dissconnect the wires depending upon the design of your power cord hook up. If the cord has a molded holding mechanism that fits into plastic retainers in the housing you will probably have to buy a new cord. But sometimes you can cut the cord after the point where the wires broke strip back the outer ord insulation and expose the insulted wires. you can purchase crimp on connectors from the hardware store and crimp them on to the stripped wire ends just like the part you cut off (use it as your model) and then plug them back into the common connection and the switch or retwist the wires and wire nut them. If you don't know howto do this take the cord with you and they will galdly crimp them on for you. Make sure the cord is strain releived like it was when you took it apart and put it the vacuume back together. One major rule, always make certain the vaccume retaines it abity to protect you from harm by making sure the modifications you make result in the vacuume going back together like the manufacturer designed it, well minus a few feet of cord.

Steven
July 2008