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This will show you how to fix a tear near the end of a Dyson vacuum hose.  I have the Dyson DC07 and it developed a tear near the business end of the hose after about 3 years.  The tear was so close to the end, I hated the thought of throwing the whole thing out when it looked like it should be really easy to fix.

The Dyson hose, when stored, hides up under a plastic sheath.  To remove it, you have to pull on the hose, which puts added stress on the hose and can result in tears as the hose ages.

I made a slight improvement as well.  Although it is a trade off, I also shortened the hose by a few inches so you can pull it out by grabbing the plastic end, instead of pulling the hose.

 
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Step 1: Tools

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You will need a flat head screwdriver, utility knife, super glue (epoxy, or other very strong plastic glue), and wire cutters.

Step 2: Take the end of the hose assembly apart

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This step is the most challenging, and based on others' experiences, the tabs are prone to breaking before coming off.  Others have overcome this using different techniques.  I've included some tips from the comments, but read through them below to get additional thoughts.
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We need to disassemble the hose end first, to cut out the bad part of the hose.

Before you gather your tools, put some water on to boil, to help make this step easier.

First, submerge the hose end in hot water, up to and including the tabs, to soften the plastic and make everything a bit more flexible and workable.  Take a quick break, and let the hose soak for about 5-10 minutes.

Now, start by releasing the two black tabs on each side to release the hose.   Hold the hose end with the lock button on top and squeeze the sides to relieve pressure on the two black tabs.  Using the screw driver, push hard in on the first black tab, then rotate the screwdriver handle towards the open end of the hose, prying the tab out of the hole, until it clicks.  Turn the hose end over and repeat for the other side.  When the 2nd tab clicks out, the hose will easily release from the hose end.

Be very careful with the gray plastic business end.  There are two small springs that are used for putting tension on the yellow lock button.  With the hose separated, these springs are lose and can easily come out if you're not careful.  They are easy to put back in place if they do come out, but they're small and could easily be lost if you don't keep a close eye on them.

Step 3: Remove the black plastic end of the hose

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Using a combination of wire cutters and brute force, remove the black plastic piece from the end of the hose.  You will be left with something that looks like this.

Step 4: (Optional) Shorten hose slightly

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This step is to make it easier to remove the hose from its hiding place and put less stress on the hose end when pulling it out.

I selected about 1.5" of hose to remove, based on a quick and rough measurement when my vacuum was fully assembled.

Using the wire cutters and the utility knife, clip the hose wire at your selected spot and then finish by cutting through the plastic hose until you have completely removed the extra section of hose.

Step 5: Cleanup hose end

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We want to cleanup and prepare the end of the hose for re-attaching.

First thing is snipping up the end to make it fit the black plastic piece again.  Make a clean cut on the end of the wire, then cut a V into the plastic hose to remove some excess so the wire fits snugly together.

When all cuts are made, wipe down the inside of the hose to remove all the years of dust accumulation.  This will help the glue stick to the hose.

Step 6: Cleanup black plastic end

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When we removed the hose from the black plastic piece, chances are the black plastic was pretty messy with hose scraps and old glue.

This is the tedious part of cleaning all the glue and glued on rubber hose bits from the black plastic end of the hose.  This is also an important step to make sure the clean hose end fits back inside the gray business end of the hose.  It's important to make sure the glue has nice surface to stick to.

Use the utility knife to CAREFULLY scrape away anything that's not black plastic.    Wear gloves if you have to.  Maybe use a vice.

I'll let you determine when it's clean enough since the last two pictures are too blurry to really see.

Step 7: Reconstruct the hose

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You are now ready to put everything back together.

First test the fitting of the black plastic piece and the hose.  Make sure they fit together well, and if necessary, clean up any extra glue, or shave off some extra plastic hose.  You want this to be snug and close fitting, and also secure so you have as much strength as possible when everything is put back together.

With everything looking good, place a good amount of super glue around the edges of the black plastic piece where it will make contact with the hose.  If you use too much, like I did, you'll end up with some on your hands.  If you use too little, you won't have a strong hold.  I prefer to err on the side of too much, but be careful to keep the glue off your fingers.

Now wait for the glue to dry.  Follow the instructions on the glue that you have chosen and wait as long as you can to make sure everything is secure.  I ended up waiting overnight because I had the time, but you don't want to test your connection before everything is dry, or you'll have wasted all your work.

Step 8: Continue reconstruction

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Once you glue is dry, make sure your work is awesome.

If everything looks good, proceed to put the gray plastic piece back on the hose end.

Line up the tabs on the black plastic piece with the holes in the gray plastic piece.  With everything lined up, push the two pieces together until you hear both sides click into place.  I chose to put the gray piece on the floor and push down hard on the hose.

With everything in place, you should have a good-as-new hose.

If you chose to shorten the hose to make it easier to pull out, when you stow the hose and clip the hose/tube assembly back into the main vacuum, you may encounter a slight bit of resistance the last few inches before everything clicks into place.  I believe the vacuum is designed to push the hose end up into the plastic sheath, but with just a bit of an angle adjustment, you should be able to easily put everything back into place without the hose end going back into its hiding place.

pondy2 years ago
I could not budge the tabs and the screwdriver just damaged them. I decided on immersion in boiling water for 10 minutes before I broke them. And I succeeded with Step 1. So boil a kettle. In a heavy pan on a wide heat-resistant shelf pour in 3+ inches of boiling water and immerse the hose end. Ensure the whole thing is stable to avoid accident, and ensure the hose doesn't twist itself and flick scalding water. After 10 minutes take it out. Then with the screwdriver (avoid those with interchangeable heads, and select a smaller head rather than larger). Press on the part of the tab that is furthest from the hose. Once that end is below the plastic end the screwdriver is eased into the hole and the locking part of the tab follows. The opposite tab will just pop out as the hose is withdrawn. Dispose of the hot water safely. Keep children and pets away.
horatio_g3 years ago
I was following these instructions but for a DC04. The tabs on the DC04 are the same colour as the body of the cuff (purple in my case). Also, to release the cuff, you also have to press in the suction decrease button at the same time as pushing in the tab on the same side as this button. (I'm taking about the cicrcular suction reduction button here, not the semi-circular wand release button further down the cuff.) Its easiest to first press in the tab on the other side and work this tab slightly up the cuff towards the hose end. Then go back to the tab on the button side. Press the button and tab at same time before working tab, again, towards the hose end. The button is on the component that slides out of cuff with the hose. Hope that helps DC04 folks!
Jo63 years ago
Thanks for the advice. I've modified two steps.

Step 2 - to get the grey end off the hose/black plastic piece, just insert your flat-bladewd screwdriver parallel to the hose between the hose and the grey end. Then a gentle push towards the centre will release the black tab easily. Same the other side.

In Step 6, I've soaked the plastic end in the sticker removing liquid that you can buy (e.g. made by HG at £3.50 per bottle). This has made it easier to remove the glue without damaging the plastic end or myself too much. Be sure to wash it thoroughly after this before trying to use the superglue.

Once again- thanks.
espydell3 years ago
Thanks a bunch! This gave me the confidence to fix something that looked fixable. Like a previous commenter I was unable to pop the tabs in on the grey assembly. I tried to squeeze it in a table vise, but ended up submerging the whole business in boiling water for 5 minutes, squeezing it some more with no luck. Once it was hot though I was able to pry up the outside plastic from the bottom... sort of destroyed the tabs and their slots so once the glue dries I may be using some duct tape around the outside. Maybe the hot water trick from the start would have solved my problems.... I think in the end it will be fine. I included some pictures of what over worked tab slots look like
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Colin Bee3 months ago

Whoa! What a superb "instructable"! Brilliant text guidance and clear pics made this job a piece of cake! Thanks hugely to bluesky, and thanks to others who added suggestions on getting those dratted tabs released! As it happens, dunking in hot water (as per bluesky's advice) allowed easy release of the tabs!

Please pay attention to his/her advice re. the two little springs that control the catch mechanism: I didn't, one sprang out and bizarrely I found it eventually right ontop of one of the kitchen wall cupboards (after I'd searched every inch of the floor and kitchen work surfaces!!).

I took the suggestion and shortened the hose, and now it is much easier to pull out - very good tip!

What can I say: saved myself a good few £££, didn't have to wait for a replacement hose to arrive, and had the satisfaction of a job well done. Many, many thanks to blueky, and Instructables of course!

Dsibb19624 months ago

Thanks for the great instructions. You saved me cost of new vac. I was done in under an hour.

JohnB208 months ago

Thanks for the great instructions. I did this in about 5 minutes using super glue. Once I got the hose on the black piece I ran a bead of super glue around the edge and let it dry completely (about 2 minutes).

TimJH9 months ago

Thank you for this - very clear, very helpful, enabled me to get the job done without wrecking the machine!! Very grateful!

JamesH211 months ago

First off. Thank you. This has been very helpful and has made things quicker and easier.

Note 1,Another Option: Before this I tried the duct tape route, which really isn't worth the trouble but..., if you're feeling lazy I think the wide thin white pipe fitters tape would work nicely. I think you can get it a couple inches wide. It's water tight so we can only assume it's "air" tight. It's extremely thin and durable. You can start the wind by winding it over itself. When you pull it tight it binds to itself.

Duct tape prevents you from storing the brush extension pipe inside the hose. Some of the sticky part of the tape always seems to get through the tear in the hose.

Note 2 Black Tabs on inside Black Coupling: I put a flat head screwdriver bit in a vice gripe then aligned one tab to it and pushed down on the other tab with another screw driver and it popped right out. I don't have a dedicated vice grip but I do have a B&D Workmate. An extra set of hands would probably do the trick.

Note 3 Attaching the hose to the Inside Black Coupling: I realized, after I cleaned it out that it's a screw.. If I aligned the hose wire to the bottom groove of the coupling, I could slowly twist it on and pressure would hold it in place, since the hose is smaller in diameter than the plastic black coupling. I wouldn't trim the hose plastic too close to the wire.

I just thought these suggestions might help.

Thank you again,

james-

archwayplus11 months ago

This is a very helpful tutorial, but whilst the preheating with boiling water in step 2 is a good idea, my attempt to separate the parts using this method was unsuccessful so I devised an alternative approach that worked better for me. In case others might be interested, my method of completing step 2 is as follows...

Use a vice to gently squeeze the plastic end piece into a slightly elliptical shape so that the vertical major axis of the ellipse provides more room for the tabs to move in. (The vice allows fine control of the amount of force used so, with care, there should be no risk of breakage.)

With one of the small black tabs now on top, align the flat bladed screwdriver with a slight lean along the direction of desired movement and give a gentle but sharp tap on the screwdriver with a small hammer. I found that this was enough to easily separate the parts.

I then followed the rest of the original tutorial.

I hope that helps.

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Cried4No11 year ago

Just wanted to give a HUGE THANK YOU for this accurate, easy to follow instructable. The cost of a Dyson is extreme (but worth it). Temporary fix with duct tape was just that.."temporary." Going to follow your easy doable advice right now. Thanks again!!

I see that this has been up for a few years. I googled "how to fix vacuum hose" and this was the top hit and amazingly enough, it was for the type of vacuum I was trying to fix. I read through your instructions less than a hour ago, gathered a few tools, repaired the hose and am now extremely grateful for your time and effort in posting these instructions and pictures. It was a snap because of your effort. Thank you!

bluesky (author)  texaspanhandler1 year ago
Awesome! And thank you!

I'm happy to hear this worked so well.
JGJ1 year ago
This was excellent. Our DC07 Animal has had a faulty hose for a long time, taped up with Duct tape till it finally went. I've managed to get it 99% fixed, although getting the black connector out took a lot more than some of the 15 minutes successes noted here. The only problem I've had was re-fitting the hose to the connector. I can't get a complete metal ring round it. Is there a proper way of doing this that, in my general DIY ignorance, I've not managed to pick up on???
Great tutorial !! I hate to throw stuff away (and PAY for replacement) when it can still serve its purpose. The boiling did not work for me. Tried it twice. The boiling left with a little crack in the gray connector portion from the black button to the yellow button.
Here's what did work. I used an exacto knife that I heated via stove flame to carefully cut some of the black button out, from the lower portion of the black button - the portion closest to the hose. This work like a gem. I think those black buttons are just too big, too tight in the whole and perhaps shaped adversely, to be pushed through enough to release.
Thank you so much! Great tutorial. Definitely had to soak in boiling water to release hose. Can't wait to try it out after filter dries!
janne06192 years ago
Thanks for the very clear directions! i knew there was a way to fix it, but would have probably done more harm than good without your instruction. Thank you very much.
amacan2 years ago
Did this in about 15 minutes with no detectable damage to the tabs. I had to slightly work the plastic to get the tabs to disengage, but it worked overall. Saved the cost of a replacement hose, and got a nice smile from the wife. Always a good thing.
russtan3 years ago
This was my first attempt at an instructables repair and it worked a treat - the instructions were clear and easy to follow - thanks for taking the time to post them, it saved me from having to buy a whole new hose.

I also damaged the black tabs removing the hose from the grey assembly, but I used a bit of sugru to remould them and they seem to be holding up nicely.

bluesky (author)  russtan3 years ago
Thanks.

I'd love to see an instructable on how you replaced with sugru, since so it seems like everyone is having trouble with this step. How long did it take you?

I feel like there must be some trick to it, but glad to see you were able to replace it.
russtan bluesky3 years ago
I temporarily taped the hose to the attachment, then I just moulded some replacements tabs out of the sugru, which bonds to the original plastic underneath - I made them slightly proud to make sure they'll hold (as in the first two pics attached). It took very little time (less than 5 minutes).

If I need to repair the hose again the sugru can be cut away to release the hose and new tabs re-moulded.

I used the rest of the sugru to make a pad on the dyson's handle where I used to find the handle cut into my fingers when I was vacuuming. (pic 3)
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quatso3 years ago
"Using the screw driver, push in on the first black tab until in clicks out of the hose end" - the tabs won't move a bit. i'm using a bit of force but the tabs form gets ruined a bit by the screw driver.
Braindekay3 years ago
Thanks for the info. I completed the task in about 15 minutes. Small amount of blood in attempting to remove the old glue but otherwise OK.
yankees20093 years ago
Tried to no end to get past step 1 without any success whatsoever. After 30 minutes of trying to get those tabs to pop ended up black taping the hose.

Cannot believe what garbage these Dyson vacuums are. Absolute junk.

I highly recommend anyone who is in the market to steer clear of these overpriced pieces of junk.
TommyTS4 years ago
thanks...worked great! I used epoxy instead of super glue -- the super glue dried too quickly before I could get the hose fully on.
Allfunktup4 years ago
I make a point of always buying pre-owned dyson's. I do this as they have a great servicing scheme where you can get a full service plus any replacement parts (even motor) included which costs £69. I got my current Animal free so the service seems like a small price to pay. Until I get the service, I will follow this guide for the hose though.
twocvbloke5 years ago
I'd have taken it to the dyson retirement home, aka the dump, cos that's where all dysons belong... :)
lemonie5 years ago
They're not good machines, far too much design over basic functionality. Nice instruction.

L
dchall85 years ago
Thanks for going to the trouble and taking pictures.  I'll bet this fix will save me serious money in the near future.  I would not have thought it could be fixed, so thanks. 

It would be nice if your pictures were more focused, but they do get the point across.