I am mechanically/electrically inclined so a power cord replacement for this unit seemed to be a pretty straightforward job. I just rec'd the replacement cord, viola! Head meet wall! The cord goes into the back of the upright portion of the unit and I have removed every screw that appears to man (including looking behind the light housing assembly) and no go on entry. I do not want to start prying as I obviously may damage something. I have been looking online for service manuals for this 10 year old vacuum, but all I find is the owners manuals whose only use at this point would be for bird cage liner.
The vacuum works great, just the cord is worn/exposed and been pulled too tight (and therefor the jacket is no longer captured, the wires are exposed) too many times for it to be safely used.
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There are many different models of Hoover Windtunnel so I can't be specific to your model, you will need to determine where the cord enters the unit and how to gain access to the internal wiring. Disconnect the old cord and attach the new cord using the proper connectors.
You can remove the entire handle and cable by unlocking the handle at the bottom above the main dust bin. There should be a lock with an arrow on it, like a rectangle which you pull upwards - this will unlock the handle with the cable. Or there may be a twist lock dependent on the vacuum you have. Replacement handles with cords are available to buy online but if you are good at wire/electrical wire replacement, you can follow online videos on how to replace the original power cord.
This procedure worked for replacing the cord on my Hoover U6425-900. At a minimum, you will need a number 2 Phillips screwdriver, wire cutter, and two electrical wire nuts and electrical tape. Remove the accessory tools from the storage compartment. Remove two screws, these are recessed. Remove the cover from the bag compartment, remove two screws located at top corners of bag compartment. You may have to open the side filter door but the accessory tool storage compartment should be free at this point and can be removed. You should see the power cord and related wiring. If you have a digital camera you could take a photo at this point in case you need a point of reference. Make note of the power cord strain relief routing and length of wire. Too much wire will make reattaching the storage compartment difficult and the routing prevents the cord from being pulled out.
On my model the wiring colors were purple, orange and white. My replacement cord had black and white wires. The orange wire will not be involved in cord replacement. Using the wire cutters clip the purple wire about three inches back from the existing terminal. If present, clip the two nylon wire ties and discard. The white wire will have a crimped on wire connector. Clip the white wire about three inches back from the existing wire connector. The old power cord can be removed by pulling it out from the rear, it should just slide out of the rubber insulating boot. If not use a set of pliers and crimp the boot from the wiring side and push it outside the vacuum housing. If you have to do this make sure you slip the boot over the replacement cord before you insert the new cord back into the vacuum housing. Remove about a half inch of insulation from the purple and white wires and from your replacement cord unless it was supplied with insulation already removed. Use new wire nuts and connect the white wires. Use the other wire nut and connect the purple wire to the remaining new power cord wire. Use some electrical tape and wrap the nuts to the wires a couple of times so they won't loosen. Make sure you route the power cord around the posts as this is the strain relief and prevents the cord from being pulled out. Reassemble and test.
You will probably have to replace the cord winding mechanism. I have never had any luck trying to repair one. Cord retracters are great when they work but it seems like they always go bad before too long. On many units you can't even replace the cord if you get a bad spot in it, you have to buy a new cord reel which can get expensive.
I had the same problem - the power cord for my Hoover Elite Upright (U5507900) was stuck a few inches out and wouldn't go any further. But when I unscrewed the rewinding mechanism, the cord had clearly gotten twisted and partly buried under itself so after some work I was able to free it. Now it seems to be working fine, at least for the moment. Note that I had to use small screwdrivers to unscrew the cord rewinding compartment, like the kind of screwdrivers you use for computer repair. HTH!
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!) http://www.elkypro.com/hoops2005/vacuum_parts/hoover/U5461-900.html
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!
ok so I took this vaccum apart completely except for the electrical and motor systems. It seems to me that without dismantling both of these systems on the vaccum you can't replace the power cord. And I wouldn't recommend taking them apart unless you know what you are doing since replacing the power cord seems to require cutting the old power cord and soldering the new one onto the old terminals. All in all its probably easier to get a new vaccum altogether.