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With all that's involved in replacing the cord and potential cord reel damage, it's more cost effective to just have the entire cord reel, complete with new cord, replaced. Less time consuming thus less costly to you. Hope it helps!
If the vacuum runs well with no other problems it may be worth buying a new cord reel. It may be less expensive to purchase a new vacuum but it may not last as long as an older machine. I have many 10 to 20 year old vacuums brought into my store for routine maintenance. Do not try to replace the cord as you are correct, the spring come flying out.
First, try standing vacuum on it's back end. Gently pull on cord and release. Try this a few times.
If this doesn't work, you'll need to take it to an authorized Aerus Electrolux store and let the service tech repair it. Although it's relatively easy to disassemble, reassembling correctly is trickier. I've had several machines come into the shop disassembled because the owner couldn't figure out how to put it together again.
Also, when taking the cord rewinder apart, there's a risk of breaking tabs that hold it together.
Hi there Johnd, SmartAlec from Nelsonvacuums.com.au here. I fix vacuums full time for a living and the first time i had this problem with the australian version of this vacuum it tok me an hour to pull it apart and back together. now i have done a dozen or so it is about a 30minute operation. I dont know what you rate your technical skill level at but i give this machine a 8/10 for hardness. It is most likely that the cord has jumped off the reel and is wedged so it shouldn't require parts but it cant be done without nearly stripping it down. There is no reset or similar for the reel. My advice unless your very confident take it to a repairer. It would be 1/2 - 1hr of labour charge only i would think.
Hope this helps.
SmartAlec
You will probably have to replace the whole reel cord. Depending on your model, on each side, there is a bar in the middle that will slide off, then the 2 halfs will come apart. They will only slide in one direction. If an older model, there are screw on the top to remove the top panel, then remove the 2 screws on the bottom and the reel cord (which is the back end of the vac)will come off. Pay attention to where the wires go so you don't hook them up wrong.
Depends on which model you have, but most of them you take off the center section, then you cab get to the 2 screws on top , and there is a screw on the bottom, then the back end will pull off. But I wouldn't try taking the cord reel apart, if that spring lets go while you are doing that, it could be dangerous. Also make sure that it isn't plugged in.
The trim pieces along the sides just pull off seperating the two housings. The back portion where the retract drum is is held by two plastic tangs on top inside. use a screwdriver to pry the ring down to dislodge the tangs. the bottom part will lift off. remove the front part using two screws just below the hinge. the retract has a long coil spring wound around a free spinning hub.
there are two "tangs" inside that engage a ratchet-pawl assembly. you'll need to rotate the drum to rewind the spring onto its hub.
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