DC24: Why Some Brushrolls Don’t Fit onto New Brushroll Motors.

This has cropped up a few times recently, so I thought we would have a post explaining it.

If you have got yourself a new DC24 Brush Bar Motor, it can sometimes be the case that upon reassembly, your current brushroll doesn’t fit the new drive cog fitted to the new motor.

This sometimes causes people to go back to the part seller and say they supplied them the wrong motor. Which isn’t correct. So here, we explain.

On a DC24, the brushroll is driven by a belt driven three fin cog, which in turn is powered by a Johnson 240vDC electric motor in the cleaner head.

Not long into production, Dyson modified slightly the design of the brushroll and the cog that drives it.

When you strip down the cleaner head on your DC24, take a look at the drive cog.

This is the early one:

Early DC24 Brushroll Cog

This is the later and more popular one:

Late DC24 Brushroll Cog

You will see that the later one has a slightly longer protrusion on there.

All new brush bar motors are the later type; the early cog is no longer available. All new brushrolls are the later type too.

So to get your machine back up and running, you have four options:

  • Swap the mechanism that has the cog on from your old motor to the new one. They clip apart. No tools requires.
  • If you dont want to swap the mechanism over, and your old cog is in good condition, you can swap it over with the new one. It comes off with a T8 star screw (if you need that screwdriver, you can find it here).
  • If your old cog is in poor condition, you can buy the corresponding later brushroll from here. (I like to replace the end cap at the same time to stop rattles.)
  • Some people choose to drill out their old brush roll a little to allow it to accept the longer, later cog. For me, that makes it more prone to rattle as you are risking it running not true, but people do it anyway.


It is worth noting that it is only the early brushroll that doesn’t fit the later cog. The later brushroll will fit either cog.

Although, if you need to replace the brushbar motor, the brushroll and the end cap, you may want to weigh up the cost of doing that against the cost of replacing the full cleaner head.


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