just pulled my dc04 power switch apart. you need to use a thin piece of wire down the side of the green switch when the switch is in the off position. wire will go in aprox 10mm. now push switch down and push wire past clip on inside of switch and wire shold go down about 20mm alltogether from edge of grey bit. hold wire in place and pull switch up, the wire sits in a groove and helps the clip bend in and the switch come out.
once you have the green switch button out the rest is pretty simple with a torx screw holding the switch mechanism in.
our power cord was damaged where it flexs each time you wind and unwind the cord up and it is pretty simple to fix once you get the damn top/green switch part off
peter
May 2007