I found the replacement part for £22 on Ebay instead of buying an entire brushbar assembly for £45.
Step 1: Tools & Equipment
- Bit driver
- No 2 Phillips bit
- No 15 Torx bit
- Replacement motor
Step 2: Disassembly: Remove End Cap and Brushbar
Twist the end cap anticlockwise and pull away from the brushbar.
Pull the brushbar out. Now's a good time to remove all that hair and gunk.
Step 3: Disassembly: Remove Caster
Step 4: Unscrew 8 Torx Screws
Step 5: Disassembly: Remove the Top Cover
Step 6: Disassembly: Remove the Floor Plate and Drive Belt
As you separate the two pieces the drive belt should slide off the large gear allowing separation.
Step 7: Disassembly: Disconnect the Motor Terminals
Step 8: Disassembly: Unclip the Motor From the Tensioning Assembly
Push the motor towards the small gear, creating slack in the drive belt.
Lift the clear plastic tab to release the motor. Retain the spring, it's prone to flying off in the opposite direction.
Step 9: Disassembly: Desleeve Motor
Re-entangle the new motor. (Half way finished!)
Step 10: Reassembly: Clip!
Ensure the tensioning spring is in position and then slide the motor towards it until the black plastic clips engage in the clear plastic retainers.
Step 11: Reassembly: Attach the Floor Plate
Step 12: Reassembly: Attach Drive Belt
Mate it with the large gear at the top of the gear as illustrated by picture 2. If you try and slide it on at the furthest point from the small gear it will be really difficult. By mating it at the top it becomes easier.
Once the teeth are engaged at the top, rotate the belt so each tooth comes into contact with the belt and pulls it on. Pushing the motor towards the large cog and depressing the spring also helps ease the belt on.
Step 13: Reassembly: Throw That Top Cover Back On!
Secure it with the 8 Torx 15 screws being careful not to over torque them, it's only plastic!
Step 14: Reassembly: Attach the Caster
Step 15: Reassembly: Slide in Brushbar and Secure With End Cap
Attach the brusbar to your Dyson DC25 vacuum cleaner and get ready to roll!
Step 16: Testing...
Important: The brush bar won't turn on until you recline the vacuum cleaner. I spent AGES debugging this trying to find out why the brushbar wouldn't rotate. There is a switch in the reclining mechanism that starts the brushbar. DOH!
Further problems: If the previous steps don't solve your brushbar problems, there could be a problem with the brushbar switch (grey) or the reset button.