Miele vacuum S4212 Polaris with SBD 450 - 3 Combination Carpet/Smooth floor tool
(Recommended for: short-pile carpeting, area rugs and smooth flooring)
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S4212 Neptune with STB 205-3 Turbo Comfort Brush
S5281 Callisto with SEB217-3 Powerbrush
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How to repair a Hoover Self propelled Windtunnel vacuum
Content This procedure should work for most all Hoover self-propelled vacuums regardless of age.
Related Post – How to Replace the Actuator Arm On A Hoover Self-propelled Vacuum Cleaner Click Here
Caution! Be sure to unplug your vacuum before performing any service!
All Hoover self-propelled vacuum cleaners have a power drive assembly located in the nozzle area near the brush roll. (key number 16 in the drawing below). The Power Drive Assembly is powered by a flat belt that runs from the motot shaft to a pulley on the Power Drive. Direction of drive is contolled by a cable that runs from the handle all the way down to an actuator lever (number 42 in the drawing below) attached to the power drive.
If the self-propel is not working there are several possible causes. The easiest to check is the belt. Remove the bottom plate and then the nozzle top cover. If the belt is broken, stretched or has fallen off the pulley, it needs to be replaced.
Next, check the cable where it should be connected to the actuator lever (number 42). That location is the most common area for the cable to break or loosen up. If the cable is broken or badly frayed it should be replaced. More on that later. If the cable is just loose then you should be able to just tighten it back down. With the actuator in a neutral position and the handle/body released so that it lays back a little; position the cable under its retainer so that there is no tension on the actuator either backward or forward. Tighten the cable retainer. Now push on the handle grip forward and then backward. You should see the actuator move slightly in both directions. You may have to fine tune this adjustment several times until you’re satisfied that with no pressure on the handle grip the actuator is exactly in neutral, and that only slight motion on the handle grip moves the actuator in the proper direction. When you’re satisfied, plug your machine in and try it for real.
To replace the cable; remove the screws from the back of the handle grip and pull the old cable out. Simply run the new cable down and follow the above procedure to tighten and adjust it.
Replacement cables should be available from most vacuum repair shops, search the internet or directly from our web site at http://vacuumcleanershop.com/Hoover_parts_by_upright_number.htm
We appreciate all feedback. Please leave a comment and let us know if this post was of any help.
This post was very helpful, especially as it has a part diagram. I have a broken actuator lever on my U6473-900 and have now removed the “power drive assembly”. How do I remove and replace the old actuator level?
I am guessing that I have to remove the nut on the far end of the black plastic pulley on what I will call the transmission axle. Then, by popping the little clip, which I believe is called an “e-clip”, off of the shaft on which the actuator level pivots, I can pull the rubber cluthes and pressure plates.
At the same time, I think I should replace the transmission axle pulley, as it has a tiny chip in the surface upon which the flat belt rides. To do that, do I pull the axle all the way out. Slop the old pulley off, the new one on, and replace the axle, while at the same time I replace what I call the cluth plates and actuator level assembly. (My name for it)
TIA
Tia,
The Actuator Lever (#42 in the drawing) is the only replaceable part on the Power Drive Assembly. To remove it; first remove the retainer screw that holds the cable in place, then remove the e-clip that is just to the right of center on the Actuator Lever, bend the ‘L’ shaped metal bracket up slightly and remove the old Actuator Lever. Replace with a new one, secure with the L bracket and e-clip and reattach the cable. Follow the procedure in the original post above to adjust the cable. Clutches, pressure plates and pulleys are not available separate, you would have to replace the complete power drive unit.
Any idea what size washer and screw are needed for parts 29 and 30. My Actuator Lever broke at the screw eye and I don’t have the screw or washer.
Thank you.
I don’t think you’ll find these parts at any hardware store as they are made specifically for this Hoover Steam Vac. If you call us at 1-877-822-8227 we’ll look them up for you.
the on off switch does not work I hear a click for the off but not the on It does not come on
Group;
Thank you for your website and forum. We have a Hoover Windtunnel upright purchased in the year 2000 about nine years ago. Model is Mach 6.1 This is a self propelled model
We are starting to get a burning smell. I have cleaned all the filters/ and or replaced them. The vacum has not overheated and has not cut out.
Any suggestions?
I have a 10 or 12year old Hoover self-propelled wind-tunnel, (green case with Y bags), that just quit in the middle of vacuuming. Model is U6425-900. Any ideas on what is wrong?
Thanks
The switch(part-13) brush on-off control; on the front of my Hoover self-propelled fell off an the plastic switch fell into the vacuum,how do I fish it out, Thanks
How do I repair my Windtunnel 6.1 – it keeps shutting off, probably overheating. Is there anything I can do fix it?
The troubleshooting of the Hoover Self propelled Windtunnel vacume realy put me in the ball park. Does the power drive assembly have to be removed to replace the actuator lever, item 42. The end of actuator lever that the cable is attached to is broken. If the power drive has to come out can you give me a tip as how to remove it.
Robert
How do I remove the green plastic cover over the motor and power drive?
Model u6425-950
I hope I can find my way back to this site. I have a commercial janitorial business, and lost all my equipment in hurricane Rita a few yrs back. To “make do” until I could recoup losses, I bought a few hoover self propelled windtunnel vac. It has been about 4 yrs now.. and I am still using them. That is really incredible considering the fact that they cover an area of about 18,000 sq ft every nite. I do run into some problems now and again.. this site should be very helpful.. thank you
Thanks so much for your help diagrams were great;will now place order for replacement parts from you, Thanks Jerry G
I have a Wind Tunnel vacuum and the self propel quit working. The plastic piece where the cable hooks into the clutch arm is broken. How do I get into it to replace the clutch arm?
Thank You,
Betty
How do I replace the “handle foot petal release”?
I have a Hoover Windtunnel from years ago and there was a recall that I think was due to faulty on/off switch and possible overheating if it wouldn’t turn off. We received a letter to go in to get the problem fixed free of charge and did. I don’t remember what year it happened, but I think it was after 2000. You might be able to look up Hoover recalls online somewhere. Hope this helps.
Laura
I replaced the actuator arm today,and after putting back together,I encountered two more probems.
1) The switch for carpet/hard will not budge when I tilt the handle forward until I bring the handle almost all the way down.At that point I can move the switch to hard,but the brush does not stop spinning.
2) When I move the handle forward,I can’t get the self-propel switch to the off position.
Steve
Have a new Self propelled Hoover Model # U64636-900. My self propell cable is broken and this model # is not on the drop down list. Was wondering if somehow I can find that part # and somewhere to get it from??? Info and diagram here are VERY helpful.
where can i get a cable for the newer U6436-900 series ???
How do you remove the hood of the vacuum to get to the cable?
hoover window bagless shuts off when warm
I like this site. Thanks for the information. I hope there is someone here to answer as I don’t see any recent posts from the vac pro.
I have a Hoover Windtunnel S3639 cannister that is just barely a year old. Friday the power nozzle stopped turning. Also the “dirt finder” lights are not on but I think that may just be a bulb or two.
Is the power nozzle/agitator operated by the fuse? I am hoping it’s not something that is very expensive as I do like the machine.
Thanks for any help you can give.
I have replaced both the flat belt and the v belt, the brush will turn when I hold it up out of the floor. The brush will not turn when it is down on the carpet, the v belt bows up and will not turn the brush roll. Any help will be greatly appreciated.
I have replaced both the flat belt and the v belt on my Hoover bagless. The brush will turn when I hold it up off the floor but will not turn when when I lower it onto the carpet. The v belt bowes up and will not turn the brush roll. Any help will be appreciated.
Brush does not rotate. Belts are o.k. the hard/carpet lever just flops around. It is either broken or disconnected but I can’t see inside, and how to disassemble is not apparent. I don’t see a key for your parts diagram, but it is either parts No.4 or 13.
Model U6439-900
Thanks for the info regarding replacing the actuator arm! Mine broke where the plastic surrounds the nut/screw holding the cable (probably from lifting the machine using the end handle instead of lower down on the body). My only hesitation was not knowing how to remove the top cover to gain access to the actuator arm, but I figured it out! Thanks for giving me the courage to try! I crazy glued the 3 broken pieces together to form the hex nut shape, and it works! We’ll see how long it lasts…surprised myself!
Anyone wanting to know how to disassemble the cover, e-mail me smjmtpdx@hotmail.com
Our Self Proplled Model U6617-900 has a broken part #41. This was found when replacing the drive control cable. The spring was shoving the piece against the control lever and I have no way of knowing what it looked like before broken. I have ordered the parts to repair but am in need of a good picture of what it looks like assembled. The diagrams do not show what or how the sping rests against to either hold the valve door open or shut. Can you help?
This was just the kind of information I was looking for. Great site.
Larry
We just moved into a place that has new carpet that sheds something awful. Our Hoover windtunnel, modelU6616-900. picks it up but the waste won’t exit the housing to go into the baglerss chamber. It jambs up there and I pull the stuff out witht he assistance of a wet vac and it jambs up again.
What’s wrong?
My self-propelled vacuum engine stops. Is there a re-set botton somewhere?
My Hoover WindTunnel will not turn off. I have to use the power plug to turn it on and off, which I know will cause more damage. I have been searching this problem and have found that others are experiencing this, but I have not found an explanation or a fix for the problem.
I just replaced my Windtunnel Activator Lever (#42) and here is the process, you will need a torex screwdriver for one screw, otherwise a number 2 philips head for the screws and a flat head screwdrive to assist with prying some tabs are the only tools you will need:
1. Remove the shroud around the beater bar, you do not have to remove the belts.
2. You will need to remove the screws that hold the top cover (#1), there are two tabs and the suction hose holder (#20 and the four screws #38). The two tabs are about midway along #18, use a flat head screwdriver to pry the tabs out, they should just slip right out.
3. Remove the suction hose, carefully but forcefully from #20, or if you removed #20, then take the hose out of the shroud number #1. #1 should now separate, if it doesn’t then look for a screw that you might have missed, the exploded view isn’t very clear. You may need to remove #25.
4. Once the shroud is off, you can now remove the actuator bar, if you the cable is still attached, then remove it, you will need a torex screw head (and maybe a crescent wrench, small for the nut if the actuator lever has broken at the cable hold down point). You will need to remove the “e”-nut, I used my philips, but there are other ways such as using a needle nose pliers. The actuator level is also held down by a right angle bracket that has a retangle hole in it, you will need to make sure that it is oriented to catch the tab on the clutch correctly, make sure to take a look at it before you do the next step. Pull, carefully, but forcefully, the right angel bracket back, now the actuator lever will come out.
5. Replace with the new actuator lever, push the right angle bracket back into place, make sure to catch the clutch tab correctly. Put the e-nut back. At this time you can replace the cable using the instructions included in the blog above.
6. Replace the shroud #1, with the screws you removed, make sure the carpet controls work, if they do not, then play around with them till they do. Press the shroud #1 until the tabs click
7. Replace the suction hose and then #20 to hold the suction hose.
8. Replace #25 if you removed it, and then replace #22.
Finally, use a label maker to make a label that says:
“Do not pick up the vacuum by the handle, use the lift handle on the back”
Your actuator lever likely broke because you picked it by the top of the handle, also, if you note, the new actuator lever likely is thicker where the control cable connects. Apparently the original was a little too thin.
Hope this helps out.
The Hoover Wind Tunnel is sure proof that Hoover will not be making a successful robotic vacuum cleaner anytime soon.
If you are experiencing a problem with the on-off switch, it is because the switch is broken (duh). By that I mean: When you took the Hoover out of the box, you had to put the control module at the top of the handle together. This means that your assembly might have been poor (not really your fault) and that the switch didn’t make the mechanical connection. The fix is fairly easy if you know how to work on these kinds of things. Get your original instructions out and reverse them. Look at the on-off switch, there should be a black tab coming out of it, if not then it is broken in the on position.
If the black tab is present, then your external interface (the one you push up or down) is broken.
In either case, the repair is fairly simple, but you will need to purchase the authorized products for safety reasons.
To get the entire I would order: Upper Handle 012-39466053
Switch Rod Pocket 37258119
Switch Button 38421098
If you are having issues with the following:
Broken actuator lever
On/Off Switch broken
Fix them, and then make sure that everyone using the Hoover Windtunnel DOES NOT LIFT it by the upper handle! There is a lift point about mid way down the back of the vacuum cleaner. ONLY LIFT it at that point!
The Hoover engineers DID NOT make the handle strong enough to lift the vacuum cleaner frequently with the upper handle! Otherwise the Windtunnel is a fine machine (although the clutch seems to be overly complex, but robust). Use the midway handle only for lifting, it is easier on your back as well.
Reply to TIM@new carpet woes
Tim, it is likely that your hose, #5 in the diagram has come loose inside of the shroud, #1, which I think should be held by #20 or something that looks like that. If that is jammed with fibers or loose then you would likely get that kind of jamming in your vacuum.
You would need to pull the beater bar out and look carefully, this will require that you remove the two belts. (Come to think of it, I did remove the belts when I did the actuator bar.)
Removing #20 will allow you to check that the hose #5 is attached correctly.
You could also use a flashlight into the top part where the larger vacuum hose attaches via two tabs that twist in. Although I am not sure.
Hope that helps.
The Brush Roller will not turn on my Hoover WindTunnel despite changing the belts. Please help!
Really helpful articles. One question – where is the list of parts corresponding to the numbers. Probably right in front of me but I can’t find it.
Thanks,
Jim Morris
Looks like I may have to replace # 13, but I am also ooking for the parts list which corresponds to the diagram……
Please help.
The beater bar on a Hoover Wind tunnel upright with bag, turn very weak ubless you bring the handle down close to the floor the the beater works like it should, any ideas?
ED,
Sounds like you just need a new belt. When you lower the handle you are taking weight off the brush roll so it is easier to turn. A stretched belt makes the brush roll slip.
How do you replace the handle release lever (#6 on diagram-P/N 38434021) on a self propelled Hoover Windtunnel machine?
My on/off switch is broken on my hoover wind tunnel Model U6439-900. I have exposed the switch and ordered new on/off switch. How do I remove the old switch from the vacuum? It looks like it is just pull it out and push the new switch into it/s place, I haven’t been able to find directions or schematics showing removal/replacemnt of the on/off switch.
I have no suction in the hose at all. Have replaced both belts and checked both filters. There are plenty of air coming in to the side filter, but no air coming through the hose and into the bag. We have checked the hose and see no cracks or holes in it. And we have followed it all the way down to the spinning brush, and there is nothing stuck in the tubage. It seems as if the motor is working, it´s spinning the brush.
Any idea what we should try next?
Does anyone know what is wrong when the vacuum does not seem to be able to pick up dirt and hair very well anymore?I have changed the belts and the brush looks and rolls fine.The only noticeable problem I see is the red light is always on .It used to go back and forth between the red and green.I also just changed the filter.I don’t know what else to do to fix this lack of suction.Anyone have any ideas? The vacuum is a hoover bagless windtunnel 2009.
how do you replace the v-belt to the self propelled
Hoover self propelled, bagged model – believe U6485900. Brand new about a year ago. Blue model. I have had to perform multiple fixes! On/Off switch stopped working twice. Drive belt fell off it’s home. Drive belt broke. Roller stopped working intermittantly. Latest issue was the roller not rotating. This time it nearly locked up the whole machine. I found the reason, but I don’t know why it had the problem. The switch that changes from carpet to hard floors – whatever that pulley looking thing is – it disengaged and I could not get it back to the carpet position. (though the switch would slide left and right) The pulley finally returned to the correct position, but I am not sure what I did to make it do that. I put everthing back together, and it held together for a 20 minute vacuum run. However, I don’t dare change that setting (to hard floors)I really don’t want to tear it all apart again.
It seems this machine has required much more maintenance than I feel it should. Previously I returned 2 other self propelled machines when the first sign of troubles began. Unfortunately I can’t find my most recent receipt – otherwise Lowe’s would have this one back by now.
Can you tell me your opinion – should this many things be going wrong with a machine not yet a year old? I don’t believe any abuse has taken place. I do use carpet powder. Is it possible this fine dust has prematurely aged parts and pieces?
Thanks, I appreciate your time