Question about Hoover U6616-900 WindTunnel Bagless Upright Vacuum

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How to replace power cord on Hoover WindTunnel upright vacuum

The cord on my Hoover WindTunnel upright vacuum is damaged from having been run over while vacuuming. I purchased a replacement power cord, agitator brush, belt, and filters from the Hoover web site.

I have installed the new brush, belt, and filters. I'm ready to install the replacement cord, but I can't figure out how to access the interior part of the vacuum! I tried removing many different screws but none of them seemed to give me access to the necessary area. Any help would be appreciated!

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  • pfriem Mar 15, 2009

    I need to replace the cord on my Hoover Model U5461-9000. I have the same problem as posted previously. I cannot seem to find access to the connection inside the machine. Removing various screws does not seem to help.


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The aforementioned solutions probably never even attempted this fix on this model. The handle does NOT need to come off. but the 5 screws on the front housing DO: 2 above the light and 3 below it. Then to get the colored housing off you need to access 2 screws on the underside that are beneath the agitator roller. To do that, obviously the 4 screws holding the bottom plate need to come off too. Here's a link to a schematic that might help as you attempt to do this, (assuming that you still do!)

Once you have the main body housing cover off, then you can access the 2 screws atop of each trunnion cover that holds the motor assembly cover halves together. If you've made it this far, then gently pry apart the motor halves keeping even as yo do. Now you can see all the wiring necessary to cut and splice. Happy cord replacing! As for me, I am headed for the store, as I am not so sure I can remember how to get the darn thing put back together. But it was fun taking it apart!

Posted on Apr 29, 2010

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  • Nova Peter Buchanan
    Nova Peter Buchanan Apr 29, 2010

    Better yet. If you can get some skinny pliers and squeeze the little "strain relief elbow" that holds the cord in place at the back of the vacuum, just enough to get the latch design to "release" then it WILL pop out. You can pull enough of the cord out to do your splicing, pop the strain elbow relief thingy back onto the cord, pop it back into the unit and walla, you are done! If you can do it THIS way, then NO screws need to be removed whatsoever to replace your cord. Sorry for all of that above. Guess I had to go thru it all the hard way to learn the easy way.

  • snakysmom Nov 07, 2010

    On my sister's model, which I just did, that would have been impossible to do. I HAD to get at the motor to remove the old cord. The wires never would have reached to the opening.

  • garybear2 Jan 27, 2011

    Disassembly instructions were accurate for model U5458-900 UNTIL separation of motor cover halves. Access to the motor wires was not possible. It was necessary to remove the headlight lens and the screw found under it securing the light bulb and DirtFINDER assembly. Thereafter it was necessary to unplug the wire connected to the DirtFINDER circuit board and remove the spongy plug at the other end. Only by doing this could I separate the covers to access the wire bundles. After cutting and removing two cable ties and electrical tape, the covers could be opened further and the two motor wires, black and white, could be separated. I removed the wire nut securing the old black wire to the blue motor wire and cut the old white motor wire about 3" from its connector (to the motor). The 'strain relief elbow' was removed with pliers as noted in the 1st comment, but also remove the wire securing screw about 2 inches from the elbow. [In order to splice the new wires to the old wires w/o disassembly as suggested in the 1st comment, this would have to be done externally on my model and the removal of the elbow would not have been necessary.] The old power cord can now be removed in its entirety from the motor compartment and back of vacuum. The securing fitting (after removal from the old cord) needs to be placed on the new cord before proceeding. I found it necessary to remove 4" of the outermost insulation from my new generic 2 wire 17/2 power cord as it would not fit through the elbow. Black and white wires were thereby exposed as well as twine. After cutting away the twine,the two wires were pressed their 4" length through the elbow . I then stripped the ends of the two wires of 3/8" of insulation for their respective splices. The elbow was then pressed into the hole it had been pulled from replicating its orientation to the securing fitting. The stripped end of the new black wire was spliced to the blue motor wire by means of the original wire nut. It was necessary for me to strip 3/8" of inch of insulation from the cut end of the old white wire in the motor compartment and splice to the new white motor wire with a wire nut I contributed to the project. [Had I had a replacement Hoover power cord, I think I would have cut the connector off of the white wire and done a splice as I did as there is little room to access the removal and installation of a new connector.] I chose to reassemble w/o tape or cable ties. I'll post another comment if that comes back to bite me. - Gary


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For the w.t.sp. you will first need a pair of **** , electrical tape, wire strippers and some wire nuts. on your handle you will see either (2) or (4) screws. remove these screws and handle. next take out all of your tools out from the storage place in front. you should see (4) more screws inside. once those are out the face plate will come off. cut the cord with the **** and cut the leads inside. you should see a purple wire and an orange wire. (purple goes with purple, the white goes with the orange) to put back reverse your steps. hope this help. if you get stuck write me back

Posted on Aug 06, 2009

  • Mark Scott Feb 03, 2011

    On my Hoover Vacuum model number U6425-900 this saved me a lot of time trying to figure out how to change the cord. Took me less than 30 min. Many thanks to maverick_bea for his solution.


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How to replace power cord on Hoover Windtunnel...
Posted by SaxTeacher on Apr 15, 2008
The cord on my Hoover Windtunnel upright vacuum is damaged from having been run over while vacuuming. I purchased a replacement power cord, agitator brush, belt, and filters from the Hoover web site.
I have installed the new brush, belt, and filters. I'm ready to install the replacement cord, but I can't figure out how to access the interior part of the vacuum! I tried removing many different screws but none of them seemed to give me access to the necessary area. Any help would be appreciated!

I would advise you to ALWAYS to FIRST UNPLUG YOUR VACUUM before beginning any service procedure.
Hoover U6616-900 Windtunnel Bagless Upright
Depending on where the cord comes out, you may want to check the owner’s manual for the exploded view of the cord area. Usually the cord comes out of the handle and there should be handle screws to release the existing cord and when you replace the cord mark the wires so that you will replace the new cord in the same manner. If it comes out of the body of the vacuum there are recessed screws that will let out into the vacuum to replace the cord. You don’t want to exceed the repairs cost to the price of what you paid for it. The decision should be yours, example: if the repairs costs are $200.00 and you paid $279.99 then @ that point you would have to decide if the repair costs are worth or do you want to pay the lower cost of repair and continue on. Just a suggestion... You may want to check with your local vac dealer. So if you need further assistance, please feel free to contact your local vacuum cleaner dealer in your area or in the yellow pages, or contact the factory phone number or website to further assist you with your questions. Telephone
Contact our Customer Service Department at 1.330.499.9499
Monday through Friday
8 a.m. - 7 p.m. EST

Don – The Vac Man
Go Ahead. Use Us.

Posted on May 07, 2008

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Dear Pfreim,
If you look, there are little things that keep the light part in place. It looks like an axle on each side. Look for the things, and there should be two screws in each.

Posted on Jun 17, 2011

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