How can I fix my Zanussi FLA 1002w Aquacycle 1000?

I've just replaced my bearings - Take loads of digi pics before you remove bolts and parts. You will need to remove the drum from case.
1. Remove the door seal. Its held on by a fancy plastic zip tie, look under the seal at about 6,oclock.
2. Lay machine on its front with some wooden blocks and a cloths on the blocks so you don't scratch the paint on the front.
3. Remove the two springs that the drum is suspended from.
4. Drive out the pins that hold the hydraulic dampers to the drum.
5. Take photos of all the components before you dissemble anything. Particularly wiring and hoses (this should have been item 1!)
6. Remove all hoses and motor wiring so that drum can be lifted free.
7. The outer plastic drum splits into two. This encloses the inner stainless drum.
8. There are numerous bolts which hold the outer plastic drum halves together. You shouldn't have to remove the concrete ballast but the removal will make life easier on some machines.
9. You may have to remove the other end of the door seal which is attached to the outer plastic drum but I suspect not.
10. The inner drum is attached to the outer plastic drum via the shaft which holds the motor pulley which in turn has the two bearings on it. Once the two plastic outer halves are split and the drum pulley unbolted, simply drive the shaft of the inner drum out of the outer plastic drum.
11. The stainless innner drum complete with spider should drop out probably along with all the broken ball bearings.
12. Drive the bearings out of the outer drum bearing housing. 13. As the metal bearing housing is probably bonded to the plastic outer drum take care not to drive the metal bearing housing out of the plastic drum while trying to drive out the bearings. I used various sized sockets and a large srew driver to work mine free.
14. I had to cut the inner race of the bearing off the spider shaft. I did this with a dremil or grinder. Then I decided to buy a whole new spider as the bronze bush that the seal runs on had a wear lip. Which probably let some water into the bearings in the 1st instance. approx £35.
15. I ordered the spider £35 and bearing kit £20 ish along with the outer drum seal £7 and bearing seal from the local force service agent. All in incl VAT £85-ish.
16. Cleaned up any rust and dirt from bearing housing so that new bearings won't take too much force to drive in. I used the dremil for this.
17. Drove bearings into drum bearing housing using old bearing shell which I ground down the OD so that it too would not be driven into the bearing housing and become stuck - The right socket or similar could be used. I never drive the inner race of bearings as you will damage them.
18. Drive the new seal in - Carefully. Note the correct direction to stop water from getting to the bearings.
19. Remove bolts which hold the spider to the inner drum.
20 Refit new spider. I used Loctite to ensure the bolts won't come loose.
21 I lubricated the bearing seal with some PTFE spray and the shaft of the spider.
22. Drive the shaft of the spider through the outer plastic drum bearings.
23. Fit new plastic outer drum seal and bolt together - evenly
24. Refit drum pulley which comes with new bolt. Loctite.
25. Re-assemble in reverse of removal.

Good luck!

Patrick

Patrick
February 2007