How do you replace the tension spring on the door?
I found the answer (see below) posted on another web site. I followed the instructions and replaced the spring. I found, as the original poster had, that the new spring works better than the original and is much more sturdy. To the original instructions, I would add the following:
1) There are about 20 screws so have patience removing and replacing the screws.
2) Step 3, "Slide off the rear panel" requires further clarification as the panel will not slide off even with all screws removed. I had to turn the oven over, with the top of the oven sitting on the work table. I then used a screw driver to lift the two tabs that hold the back panel to the bottom panel. With the tabs lifted, the back panel will rotate away from the oven along the edge where back panel slides into the top panel. The back panel can then be slid out. I have included three photos that show this step.
3) Step 7, "Re-attach feet": Be sure to use the guides on the bottom of the oven to slide the foot assembly onto the oven. I had unsuccessfully tried to screw the feet onto the oven without using the guides.
Oringinal instructions for replacing the broken spring:
Just repaired this yesterday.
Got a spring from Lowes (Hillman Part # 543028 for about $4), it's larger than the original but seems much sturdier, original is really thin metal. Fit the space provided without problem.
Oddly, end result was a more 'giving' spring action, prefer it to original, which loved to snap shut unless door was 100% opened (ie fully 90 degree open).
This is for BOV800XL:
1. Remove all rear screws
2. Remove feet entirely
3. Slide off rear panel
4. I was not able to remove top housing - but I was able to gently pry sides open just enough to thread the new spring with a little ingenuity and effort. Watch out for sharp metal edges everywhere.
5. Slide back in (remember that top edge goes under the top edge/lip)
6. Put all screws back in
7. Re-attach feet
Good luck!
Lee, thanks so much for your contribution!
Good to read the above comments.
Please note that you do not need to use the Hillman spring. You could use a different type of spring. The original spring has an overall diameter of about 5 mm and a spring length of about 80 mm with ends of about 25 mm on bot sides and hooks to go into the holes for the spring assembly.
I would also like to add:
4. Do not try to completely remove the top housing. Remove one side completely and the other side half attached. As stated, just leave some room to manouvre the spring into place. Screw the top back in once the spring is in place.
5. If you do not know what is meant with "remember...", you will end up unscrewing all screws because you have to tuck the top lip under the edge before screwing in. Pay attention to this.
7. This is a tough one for me. The guides described is the cylinder-shaped protrusions that meet their counterpart on the base of the unit (I assume). Press the foot assembly in, and if you are lucky the holes in the guides align with the threaded hole in the base. Mine do not, and I was unable to screw these in, no matter what I did. So, I was able to screw the feet assembly onto the base with the 2 pair of screws only. The middle two guides were not screwed in (: in my case.
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Thanks to all who contributed here.
8+ year old Breville 810XL, working great but spring broke.
Lowes still has the perfect spring, Hillman #543183.
Directions here and other websites good.
Be careful of striping all those smaller panel screws, I almost stripped three of them.
Bending out the side panel and working with the small gap to get at the spring was challenging but doable.
Don't worry if you can't get all the little screws of the foot assembly back in. The four longer screws with foot assembly aligned work fine. I couldn't get one of those in the little tab that comes off the side panel.
I followed these instructions to replace the door spring in my Breville and it worked great. The spring I used was sized at 11/32" x 2 3/8" x .035" -- I think the same size as others here -- and I bought it at Lowe's but I couldn't find the other two part numbers listed here, so maybe they changed the part number again. The one I used was Item #422427 Model #543183. Here's a picture of it:
Thanks to everyone who commented as I just replaced the broken spring on my BOV800XL. Bought Hillman Model #543183 at a Lowes $3.28 and it works great. Had the same issue with not being able to pull the side out as the front was stuck so I opened it as much as possible without bending the the metal. I had to straighten the front hook to get into the lever hole but just used a plier to squeeze close afterwards. A long nose plier was a key tool.
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9-3-15
I checked with Lowe's and Home Depot yesterday and neither carry replacement parts for small appliances... haven't in years. Appreciate ideas of where I can purchase a door spring for the Breville BOV800XL toaster oven (or generic tension spring that will fit). Can't find it online, or at local parts shops (they've stopped providing parts/servicing small appliances--major appliances only); Breville said as of January of this year, they no longer provide door springs to other companies to sell. They claimed it was a liability issue.. something about customers doing poor repair jobs (liability? say what?). Truth is, they realized they could make additional profits by not supplying certain parts (parts that regularly fail, by chance?) to other parts distributors, and offering customers service agreements ($119). Hmmm... $3-4 part/do the work yourself versus $119 plus shipping....
Thanks for ideas of where I can find another tension spring to fit the Breville BOV800XL. btw, Breville told me the dimensions were 3/8" diameter x 4" long, but I read the above poster saying make sure it's at least 6" long. Thank you!
Ended up reusing the old broken spring, joined tightly to a new small spring to pull and span the distance to the back. The hole in the door arm is so small, it's all but impossible to thread since you can't pull the side out far enough...very frustrating, but it works.
Big Thank You to Lee Liho. Bought spring Hillman Part # 543028
at Lowes (Mississauga)$5.99. 1/2 hr to replace. Inserted the small
hook into tiny hole on lever (had to straighten hook a little,insert into
tiny hole, pull with long nose pliers, re-bend the hook) Bigger hook
into hole on frame of oven. Breville customer service was not helpful.
Hillman re numbered this part. It is now #540198. I got mine from the following website www farmandfleet
Cost is $2.49 and shipping $6.50. Hook spring from arm of door to hole in back door frame. Works perfectly! Thank you for the directions on this site.
Hoping for help on my breville door spring replacement. Same model. I can see the glide piece/bar that one end of the spring attaches to. But where does the their end of spring attach to? That's where I am stumped. Thanks.
The spring attaches at the very back of the oven. The spring runs along the entire side of the oven and connects to a hole at the back of the oven.
I bought the Hillman 2-Pack 4-in Zinc-Plated Steel Window Screen Tension Springs
Item # 422427 Model # 543183 at Lowes for $3.28. Thank you everyone for the instructions. I just repaired our oven last night after years of daily use. We bought the oven the 1st year it came out and it's still going strong!
Same problem. I could've fix it yesterday but could not find any location for the rear end of the spring to attach to? I guess I'll tear it apart.... again & drill a hole if I have to!
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Thanks to all for helping me. I just did this repair this week and it worked well. Unfortunately Lowes doesn't carry the right spring anymore, and seemingly no one does. I called Hillman who has no idea, or doesn't care to look up, who carries the right model number.
So, I went the to spring ailse at Lowes with the old spring I had taken from the oven. I picked something similar and it works fine. I think it is a bit over-streched because although the door stays open at 45 degrees and rebounds nicely before that, past 45 degrees it just falls down, although not as hard as before. Ok, that's my update.
I brought a Lowe's Hillman Part # 543028 from Lowes.ca. The diameter is quite bigger than the original but it works fine.
I found that as of Nov 2022 Breville was once again willing to sell the spring to consumers--I only had to reply "I understand" to an email the representative sent to me while we were talking that said "Breville doesn't think consumers should fix their own toasters". It cost about $2 + $5 to ship. However, I couldn't wait the 10 days for it to arrive and put in the Hillman #543183. The Hillman substitute is acceptable, but has less tension and lets the door drop a bit faster than I'd like. I'll use the spare OEM spring I now own when the Hillman gives out.
I just called breville and they said they don’t sell parts. Did you call or email them?
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