The Complete Dyson DC04 Parts Guide: What You Need to Keep Your Classic Dyson Running
The Dyson DC04 is what we at Dyson Medic call “the Ford Transit of Dysons” — it does exactly what you want it to do, decade after decade, without fuss. Built in the late 1990s, this vacuum monolith helped establish Dyson’s dominance in the UK vacuum market, and thousands of DC04s are still working hard in homes across Britain today.
But when something finally does wear out on your DC04, finding the right replacement part can be challenging. Dyson discontinued official parts support in 2014, essentially hoping to relegate these brilliant machines to history. They’d rather you spent £300+ on a new cordless or “Cinetic” machine.
However, the aftermarket has stepped up. Manchester Vacs has ensured that almost every part for the DC04 remains available, so you can keep your trusty vacuum running for years to come.
Understanding Your Dyson DC04 Model
Before ordering parts, you need to to understand which type of DC04 you have. There were nine colour variants, but more importantly, there are two fundamental types:
Clutched models (with brush control) – Including most yellow/grey, De Stijl, Absolute, Zorbster (lavender/grey), and some other variants Non-clutched models – Including green/grey (silver/lime), DC04i (blue/grey), and Constant Max (silver/orange)
If you’re not sure which type you have, this forum tutorial explains the difference and shows you how to identify yours.
Why does this matter? Because certain parts — particularly hoses, cleaner heads, brushrolls, and belts — differ between clutched and non-clutched models. Ordering the wrong type means delays and frustration.
Dyson DC04 Essential Maintenance Parts
Power Cords (Flex/Cable)
One of the most common DC04 wear items is the power cord. Early Dyson models used a rather flimsy 0.75mm pale grey flex that often failed where it entered the machine. Later models used a more robust 1mm dark grey cable.
The quality aftermarket replacement Manchester Vacs stocks is a proper 1mm, dark grey, 10.9m cable with correct terminals for all DC04 models and a cable tidy clip already fitted. It’s longer than most aftermarket cables and far superior to the cheap Chinese ones flooding Amazon and eBay.
This cable fits DC04, DC14, and DC24 models. Cross references: 916588-01, 908578-06, 914259-29, 914259-23, 914259-02, 911859-02, 5031685212902, ES1440604, ES966394, ES1117626.
Buy the DC04/DC14/DC24 Power Cord here
Read the detailed guide: Where to Buy a Replacement DC04 Power Cord in the UK
Tutorial: How to Replace the DC04 Mains Cable
Filters
The DC04 uses two main filters:
Pre-motor filter – A washable sponge filter and holder that sits in the top of the cyclone. This should be washed regularly (monthly with heavy use) under running water and left to dry completely before refitting. A clogged pre-motor filter is one of the most common causes of suction loss.
Post-motor filter – Depending on your model, this is either a pad-type filter or a HEPA filter that sits below the cyclone unit. These aren’t washable and should be replaced when they become discoloured or start to smell.
Regular filter maintenance is genuinely the secret to keeping any Dyson running well for decades.
Pre-motor sponge filter & holder for DC04
Post-motor HEPA filter (DC04/DC05/DC08/DC19/DC20/DC21/DC29)
Post-motor filter pad (DC04/DC05/DC08/DC19/DC20/DC29)
Learn more: DC04 Filter Service Guide
Belts and Brushrolls
SPECIAL OFFER: Genuine Dyson Brushroll & Soleplate Kit for Non-Clutched Models
If you have a non-clutched DC04 (green/grey, DC04i, or Constant Max), pay attention to this: Manchester Vacs has secured Dyson’s final ever stock of the genuine brushroll and soleplate kit (part number 913868-01). These are genuine Dyson parts – not aftermarket copies.
Why does this matter? The cheap aftermarket versions that others sell are absolute rubbish. They vibrate, they don’t fit properly, and they’ll drive you mad. Manchester Vacs only stocks the genuine article because the copies simply aren’t up to standard.
While stocks last – once these are gone, they’re gone forever. Dyson has discontinued production, so this is your last chance to get a proper genuine kit at an amazing price.
Get the Genuine Dyson Brushroll & Soleplate Kit (913868-01) – Final Stock
For clutched models: The clutch mechanism on DC04s uses a motor drive belt and a separate brushbar belt. These can wear or snap, leading to poor carpet pickup. You’ll know the belt has failed if the brushbar isn’t spinning when you’re vacuuming carpet.
Genuine Dyson belts are no longer available, but quality aftermarket replacements work perfectly. When changing belts on a clutched machine, invest in a proper belt removal tool — trying to do it without one is an exercise in frustration and bloodied knuckles.
The brushroll itself (sometimes called a beater bar or agitator) can wear down over time, particularly the bristles. If your carpet pickup is poor even with fresh belts, check whether the brushroll bristles are worn down to nubs.
Part numbers for clutched brushrolls: 908724-01, 911975-01, 911976-01, 920235-01
Clutched brushroll (DC04/DC07/DC14/DC33)
Clutch belt set (motor drive belt + brushbar belt)
Clutched soleplate (DC04/DC07)
Belt/brushbar removal tool – essential for clutched models
For non-clutched models: These use a different belt configuration and a different brushroll design. Make sure you’re ordering the correct non-clutch versions.
Non-clutched drive belts (pack of 2)
Tutorial: DC04 Belt Change Guide
Dyson DC04 Common Replacement Parts
Wand Handles – Manchester Vacs Own Product
After 10-20 years, the plastic on DC04 wand handles can become brittle. The tool holder on the back breaks, or sometimes the handle snaps altogether. This isn’t bad design — it’s just aged plastics doing what they do beyond their expected service life.
When Dyson discontinued the part in 2014, Manchester Vacs developed their own replacement. These aren’t just any aftermarket parts – they’re manufactured to Manchester Vacs’ specifications and have been proven over thousands of sales since 2016.
These grey wand handles have generic silver fittings and fit all versions of the DC04 – clutched and non-clutched, every colour variant. They’re a direct replacement that works perfectly.
Original Dyson part numbers replaced: 902970-12, 902970-14, 902970-13, 902970-22, 902970-16, 902970-18, 903508-03, 903508-09, 903508-08
Buy DC04 Wand Handle – Fits All Colours
Related wand components:
Wand handle release catch – Manchester Vacs replacement part
Swivelling wand cover (top cap) – Manchester Vacs replacement part
Curved top cover from wand handle – Fits DC03 and DC04, replaces part numbers 903325-01, 904748-09, 903325-05, 903325-03, 904748-07, 904748-08, 903325-02, 903325-06
Wand handle release spring (900199-06) – Fits DC03, DC04, DC07, DC14, DC15, DC33
Read more: Where to Buy a New Wand Handle for a Dyson DC04
Clutches
Clutches are long since discontinued, but while stocks last, you can get a replacement rebuilt clutch here: Dyson DC04 clutch
Telescopic Back Hoses
The extendable hose on the back of your DC04 can crack, split, or the fittings can break. Replacement depends on your model type:
Clutched DC04 hose: Uses specific end fittings. Cross references: 911861-01, 901731-10, 901731-09, 901731-12, HSE92, 901731-01, 901731-03, 901731-11, 901731-14
Non-clutched DC04 hose: Different fittings than clutched models. Currently supplied with a green lower fitting regardless of your machine’s original colour. Fits DC04 grey/green (silver/lime), DC04 Constant Max (silver/orange), DC04 Independent (grey/light blue). Cross references: 912391-01, 903510-03, 903510-04, 903510-06, 903510-05, ES1062075
Buy non-clutched DC04 back hose
Original hoses came in various colours to match different DC04 variants, but these are all discontinued. The replacements work perfectly but may not match your machine’s colour scheme.
Internal Hoses
There’s a short internal hose on the underside of the machine (not the main back hose) that can perish over time. Again, clutched and non-clutched models use different hoses.
Manchester Vacs only stocks genuine Dyson versions of this part because the cheap aftermarket ones are poor quality — some don’t fit properly, and others are too stiff to install without damaging the machine.
Internal hose for non-clutched DC04/DC07/DC14/DC33 – Genuine Dyson part
Internal hose for clutched DC04 – Recycled genuine Dyson part
Cleaner Heads (Base Housing)
The cleaner head (also called the base housing or floorhead) houses the brushroll and motor-driven brush mechanism. If yours is cracked or damaged, recycled genuine Dyson cleaner heads are available in various colours for both clutched and non-clutched models.
Bear in mind these are recycled parts, so exact colour matches can’t be guaranteed, and some cosmetic marks from previous use are normal.
Remember: If you’re not sure whether your DC04 has a clutch, check this forum tutorial before ordering parts.
Dyson DC04 Motors and Electrical Parts
Replacement Motors
Most DC04 models use what’s called a “YDK” motor (motor codes starting with YV). However, the lime green/grey DC04 and the pale blue/grey DC04i originally came with an “Ametek” motor.
For standard YDK motors (most DC04 models):
YDK (YV) Motor for DC04/DC07/DC14/DC27/DC33
For DC04 models originally fitted with Ametek motors (green/grey and blue/grey DC04i):
The original Ametek motor is long obsolete. Manchester Vacs offers two solutions:
Option 1: Motor + adaptor kit (complete replacement solution)
Ametek Motor Replacement Kit for DC04 Silver/Lime
This includes a quality YDK motor plus the adaptor kit (replacement motor rubbers and sealing ring). You simply discard your old motor rubbers and ring, fit the new ones supplied, and you’re good to go. One advantage: if you need to replace the motor again in future, you can use a standard YDK motor.
Option 2: Adaptor kit only (if you already have a YDK motor)
If you’ve already bought a standard YDK motor elsewhere and discovered it doesn’t fit your Ametek-fitted DC04, this adaptor kit is what you need. It includes the replacement motor rubbers and plastic sealing ring that allow a standard YDK motor to fit where an Ametek motor was originally.
Important motor fitting advice: Motors rarely fail prematurely when fitted by someone who knows what they’re doing and uses fresh filters. If you’re attempting a DIY motor swap, NEVER use a hammer on the motor shaft. Seriously. It’s immediately obvious when this has happened, and it voids any possibility of return.
Tutorial: DC04 Motor Change Guide
On/Off Switches
The DC04 switch is notoriously tricky to access without the proper tool. If you try to remove it without a switch removal tool, you’ll almost certainly damage the switch housing or the button itself.
DC04 On/Off Button Removal Tool
DC04 On/Off Button (recycled, various colours)
Replacement switches are recycled genuine Dyson parts that Manchester Vacs engineers have tested for reliability.
Tutorial: DC04 Mains Cable and Switch Removal Guide
Switch Housing
If you’ve already chewed up your switch housing trying to remove the button without the proper tool (we’ve all been there), replacement housings are available as recycled parts.
Dyson DC04 Cyclone and Bin Components
Dust Bin
The clear perspex bin can crack or become cloudy with age. Replacement bins fit any model or colour variant of the DC04. These are recycled genuine parts that have been cleaned, though some very minor scratching may be present.
Cyclone Components
Various cyclone parts are available, including: – Cyclone top assemblies (recycled, various colours) – Inner cyclone cones with shrouds – Bin flap assemblies – Top handle units for the cyclone – Filter catches and clips
Most of these are recycled genuine Dyson parts. Colours cannot be guaranteed to match your specific model.
U-Bends
The u-bend (the curved tube that connects the cleaner head to the main body) was originally made in various colours. Replacement u-bends are available as recycled parts, though colour matches cannot be guaranteed.
Dyson DC04 Tools and Accessories
Onboard Tools
Standard Dyson tools fit the DC04, including: – Stair tools (upholstery tools) – Brush tools (dusting brushes) – Crevice tools
We stock high-quality compatible tool sets that fit all DC04 models. These typically come as a three-piece kit with all the essential attachments.
Learn how to use them: DC04 Tools, Wand & Back Hose Tutorial
Tangle-Free Turbine Tools
For pet hair and stubborn dirt on upholstery or stairs, reconditioned Dyson Tangle-Free Turbine Tools are available. These work with most mains-powered Dyson models, including the DC04.
Essential Tools for Dyson DC04 Repairs
Working on a DC04 isn’t rocket science, but having proper tools makes the job infinitely easier:
T15 Torx screwdriver – With a minimum 100mm shaft (tamperproof tip). You literally cannot disassemble a DC04 properly without this.
T15 Torx Screwdriver (100mm+ shaft, tamperproof)
Belt/brushbar removal tool – Essential for clutched models. Makes belt changes easy instead of a nightmare.
Belt/Brushbar Removal Tool for DC04/DC07/DC14/DC33
Switch removal tool – Prevents you from destroying the switch housing or button.
If you’re planning to maintain or repair your DC04 yourself, investing in a proper Dyson trade tool set is worthwhile. These include all the specialized tools you’ll need.
Unofficial Dyson Trade Tool Set (complete kit)
Read: Dyson Trade Tool Set Guide
Special Dyson DC04 Variants
DC04 Zorbster
The Zorbster was a unique variant made in grey and lavender, designed to double as a carpet dry cleaning machine. It has an aperture on the front that accepts a hopper for dispensing Zorb crystals.
While they were never terribly popular as carpet dry cleaners, most owners just used them as regular vacuums. If you have a Zorbster and need parts, note that some electrical components (particularly motors) may require wiring adjustments compared to standard DC04 models.
Specific Zorbster parts available: – Main body housing (recycled) – Carpet cleaning hopper (rare) – Thermal cut-out (TOC) from motor
Dyson DC04 Schematics and Technical Diagrams
For anyone tackling repairs, detailed exploded schematics showing how the DC04 goes together are invaluable. Manchester Vacs hosts these technical diagrams on the forums:
These show every component and how they fit together, which is particularly useful for complex jobs like motor replacements or full rebuilds.
There’s also a complete step-by-step guide for a full strip down and rebuild:
DC04 Complete Strip Down and Rebuild Guide
Getting Expert Advice
If you’re unsure about which part you need or how to fit it, don’t guess. The Manchester Vacs forums are full of experienced Dyson repairers and enthusiasts who can help identify the correct part for your specific model.
The DC04 community is strong, and most common problems have been solved many times before. Search the forums, and if you can’t find your answer, create a new topic — someone will help.
Why Keep Your DC04 Running?
You might wonder whether it’s worth repairing a 20+ year old vacuum when you could buy something new. Here’s why thousands of people choose to keep their DC04s going:
Built to last – The DC04 was engineered before planned obsolescence became the norm. These machines were designed to be repaired and maintained indefinitely, like a Morris Minor or Trigger’s broom.
No unnecessary features – The DC04 doesn’t have expensive HEPA assemblies that cost £50 to replace, or complex computerized systems that fail. It’s mechanically simple and robust.
Strong suction – A well-maintained DC04 still outperforms many modern machines. Cyclone technology hasn’t fundamentally changed; marketing has.
Environmental responsibility – Repairing a perfectly good vacuum instead of binning it for landfill is the right thing to do.
Economic sense – A £20 motor or £15 cable beats a £300+ new machine every time.
Common Dyson DC04 Problems and Solutions
Won’t Stand Upright
Usually, it’s a simple fix that takes seconds. Follow this guide
Loss of Suction
Check and wash the pre-motor filter first. If that doesn’t help, check for blockages in the hose, wand, or cleaner head. Post-motor filter replacement may help too.
Poor Carpet Pickup
Check belt condition and brushroll wear. Replace if necessary. Make sure the clutch is working properly (clutched models).
Machine Cuts Out or Smells Burning
Likely overheating due to a clogged filter or airway blockage. Clean filters and check for obstructions. If the motor has genuinely burnt out, replacement is straightforward.
Noisy Operation
Check for debris wrapped around the brushroll. If the motor itself sounds rough, the bearings may be wearing — usually time for a motor replacement.
What else?
The Dyson DC04 represents vacuum engineering at its finest — simple, effective, and built to be maintained for decades. While Dyson has moved on to more profitable disposable machines, the aftermarket ensures that your DC04 can continue doing its job for years to come.
Whether you need a simple flex replacement or a full motor swap, almost every part remains available. With basic tools and a bit of patience, most repairs are within reach of a competent DIY enthusiast.
And if you get stuck? The Manchester Vacs forums are there to help, and the shop stocks virtually every part you might need to keep your DC04 running indefinitely.
About Dyson Medic and Manchester Vacs
The original dysonmedic.com site (linked throughout this guide) is the oldest Dyson DIY repair site on the internet. We’ve been helping people fix their Dysons since the early days, long before it became fashionable. Manchester Vacs are the original Dyson specialists — we were repairing, advising on, and supplying parts for these machines when most others were still telling customers to just buy a new one.
That experience matters. When we tell you the aftermarket brushrolls are rubbish, or that you need a proper switch removal tool, or that our wand handles are manufactured to proper specifications — we’re speaking from decades of trial, error, and fixing thousands of Dysons.
We’re not here to sell you what you don’t need. We’re here because we genuinely believe a well-maintained DC04 is still one of the best vacuum cleaners ever made.
Related Articles
Where to Buy a Replacement DC04 Power Cord in the UK
Where to Buy a New Wand Handle for a Dyson DC04
Shop DC04 Parts: Manchester Vacs DC04 Spares
Need Advice? Dyson Forums