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To replace Junior’s Left or Right wheel, you’ll need a Phillips head screwdriver, the flat head screwdriver included in his box, and a new left or right wheel.
Before starting any repair on Junior, turn his side power switch OFF and remove his dustbin.
Then, flip Junior over onto a flat surface and remove his side and main brushes using the flat head screwdriver.
Keep all removed screws and parts safely aside, as they may be needed for later re-assembly. Use a Phillips head screwdriver to remove the 7 screws on Junior’s underside that hold him together.
There are 5 screws along the edges of Junior: One screw on each side of the front wheel.
One screw to the right of the main brush motor. And one screw on each side of the dustbin. The final two screws are in Junior’s brush compartment.
Junior’s cover is no longer secured, so hold the top and bottom together as you carefully flip him back onto his wheels.
Grip Junior’s cover from the back and lift up to expose the mainboard.
Slide the power inlet down and tuck it somewhere safe to avoid compressing its wires.
To detach Junior’s cover completely, disconnect 4 circuit plugs:
Two at the lower edge of the mainboard, near the wheels.
And two more at the top edge, near the bumper.
Junior’s cover is now completely detached and can be set aside for the rest of the repair.
To access the left or right wheel, you must first remove the wheel cover.
Remove the 6 screws securing the cover onto Bob:
You may wish to lift and move the main brush motor and power switch out of the way to reach two of these screws.
Two are next to the mainboard. Two are on either side of the left wheel, one above and one below. Lastly, two more screws are on the right wheel, one above and one below.
Once all 6 screws are removed, lift the wheel cover up and unplug it from the mainboard. Place it aside for now.
Be sure to keep the wheel’s springs safely on-hand for later reassembly.
Lift the wheel up and disconnect its circuit plug from Junior’s mainboard. Press the side tab and pull up to unplug.
If there is any glue holding the wiring on Junior, use a screwdriver to carefully break it off.
Now place the new wheel in the open space. You will have to prop up Junior’s back a few inches to insert the wheel. Once the wheel falls in place, install its 2 screws.
If you are replacing the left wheel, feed the wires around the edge of Junior’s bottom before attaching the circuit plug to the mainboard. Ensure the wires are not stuck under the main brush motor or sticking out of place.
If you are replacing the right wheel, feed the wires around the closest screw post underneath the mainboard. Then, pull the wires back out before attaching the circuit plug to the mainboard.
Replace the two springs on top of the wheels.
Plug the wheel cover back onto the mainboard. Then, carefully align the cover with the screw posts on Junior. Clear the area of any wires than may become compressed underneath the wheel cover. Make sure the springs on top of the wheels do not move out of place as you push the cover down.
Install all 6 screws previously removed from the wheel cover. There were 2 just behind the mainboard, 2 around the left wheel, and 2 around the right wheel.
Reattach all 4 circuit plugs connecting Junior’s cover to the mainboard.
There are two that connect to the top edge of the mainboard. And two more that connect to the bottom edge.
Remember to slide the power inlet back into its space on Junior’s cover. Align the cover’s edges precisely. Then, flip Junior over onto a flat surface.
Ensure that no wires are compressed in the main brush compartment or visible at the edges of the bumper. If so, take a step back and lift the cover to tuck the wires into the appropriate spaces inside Junior.
Once the wires are all safely tucked away and Junior’s cover is aligned properly, reinstall all 7 screws previously removed from Junior’s underside.
Install the main brush and dustbin before your next use and Junior is completely re-assembled.