DC40 Vacuum Repairs: What You Can Still Fix, and What Dyson Would Rather You Didn’t
Let’s talk Dyson DC40 vacuum repairs. If you’ve still got a Dyson DC40 lurking around, the question is simple: is it worth fixing, or should you just bin it? That’s what we’re looking at today.
These are getting to the age where faults are common, spare parts are becoming more hit and miss, and repair costs can sometimes outweigh the value of the machine. But not always. So let’s take a proper look at what’s still fixable on a DC40, what isn’t, and when to draw the line.
DC40: A Turning Point in Dyson’s History
The DC40 sat right in the middle of Dyson’s upright range. It was smaller than the DC41 and DC55, but bigger than the compact DC50. It was intended as the one-size-fits-most model, and for some years, it did well.
It was also the first Dyson upright to get rid of the old back pedal recline mechanism. On earlier models like the DC25, people used to stamp their foot on the cleaner head to recline it, often breaking the pedal assembly. So Dyson did away with that entirely. From the DC40 onwards (including the DC41, DC50, and every upright since), the machines just recline automatically when you pull them back.
That seemed like a smart move at the time, but it introduced a much more complex internal mechanism — one that still defeats many home repairers. The recline and steering setup inside the ball is a fiddly, tightly packed arrangement of springs, levers, and pivots that’s not exactly intuitive to take apart or reassemble. If you’ve never done one before, it’s very easy to get lost, which is why we often end up with boxes of half-disassembled DC40s dropped off in the workshop.
And here’s the kicker: Dyson still sells an upright vacuum today that’s based on this exact platform. The most current model listed on their website is the Dyson Ball Animal Complete, which we know internally as the UP22 (or UP24 in some versions). It’s effectively just a facelifted DC40, dressed up with some racing stripes, a few tweaks, and a bigger price tag, but under the skin, it’s the same old machine.
What’s interesting about the DC40 is that it marked a clear change in direction. The DC40 was really the start of the rot. The mains-powered models that came after it were mostly the same machine. They looked a bit jazzier, shared lots of parts with the DC40, but nothing actually improved.
This is the point where Dyson stopped being a vacuum cleaner company and started becoming a tech brand. They redomiciled to Singapore, shifted their focus to the Asian market, and started churning out cordless machines, fans, hairdryers, earphones, and the rest of it.
It also marked the beginning of what we now recognise as built-in obsolescence. Dyson machines became harder to repair, parts supply to the trade was quietly restricted, and key components were retired earlier than necessary. Despite all the talk of “Right to Repair”, Dyson increasingly made it difficult for independents to keep older machines going. Many ended up in the bin.
The Common Faults and What We Fixed
The good news is that a lot of parts for the DC40 are still available, and some of the common faults are easy and cheap to fix.
One of the early weak points was the red cyclone clip. On very early DC40s, the clip would snap, and of course, Dyson didn’t sell it separately — they wanted you to buy a complete cyclone assembly. We solved that years ago by manufacturing both types of red clip ourselves. When you buy one from us, you get both versions in the pack. Fit the one you need, bin the other, job done.
Power cables were another pricey item, especially if you didn’t want to terminate the ends yourself. Again, we had our own cables made — properly moulded, fully finished, and as good (if not better) than the originals.
The cleaner heads are another known issue. Dyson being Dyson, there are two types: the early version without a red slider, and the ERP version with one. The brushroll motors inside these do fail eventually, but you can still buy replacements. The heads themselves are still available, too, and both versions are interchangeable. So this isn’t usually a reason to scrap the machine.
The PCBs that control the cleaner heads, interestingly, are generally reliable. We rarely see those fail.
When to Call It a Day – The Motor Problem
The main thing that tends to kill these machines off is the motor inside the ball.
Dyson used several versions, and there’s no reliable aftermarket option. If you want a new one, you’re looking at £70–£100 for a genuine motor, if you can even still get one. By the time you’ve fitted it, added a new filter or two, maybe a cable or a hose while you’re in there, you’re pushing £150 or more. At that point, most people would rather buy a refurbished machine or just put the money towards a new one.
Used motors are a gamble. People sell them on eBay claiming they’re tested, but most of the time that means someone switched it on for five seconds and decided it sounded fine. It probably isn’t. You might end up replacing your worn-out motor with another worn-out motor.
One sign that a motor is on its way out is a high-pitched shriek when running, or a long, wheezing noise as the machine slows down. If you hear that, the bearings are going, and it’s only a matter of time.
So the reality is: if your DC40 needs a motor, it’s probably not worth fixing unless you have the part already or happen to get lucky. That’s the main reason we see fewer of these coming in now. It’s simply not cost-effective.
DIY Dyson DC40 Vacuum Repairs – Doable, but Not Always Fun
If the motor is still OK, the rest of the machine is usually worth repairing. But be warned, the DC40 is not the most user-friendly machine to work on.
The recline and steering mechanisms, the way everything is crammed inside the ball, and the fiddly internals can be a bit of a nightmare if you’ve not done one before. We occasionally get people bringing us a box of parts into our Manchester Dyson repair centre and asking if we can put it back together. If that’s you — yes, we can.
But don’t say we didn’t warn you about the complexity of DC40 vacuum repairs.
Watch the Full Discussion
If you’d rather watch the full chat, here’s the video version of this article. You’ll hear more about the parts we’ve made to keep these running, and a bit more commentary on Dyson’s design direction and what we see in the workshop.
DC40 Vacuum Repairs: Spare Parts and More Help
If you’re fixing one of these yourself, we stock all the DC40 spare parts you’re likely to need — including red clips, power cables, hoses, filters, brushroll motors, and more.
DC40 Spare Parts Page
DC40 Strip-Down Guide on the Forum
You’re also welcome to join our forum if you want advice, want to show us what you’re working on, chat about vacuum cleaners, or just want to moan about your Dyson.