Patagonia Black Hole® Wheeled Duffel Wheel Replacement

Written By: Zach Mueller

Comments: 2

Patagonia Black Hole® Wheeled Duffel Wheel Replacement

Difficulty

Moderate

Steps

Time Required

10 - 20 minutes

Introduction

This guide will show you how to assess damage and replace the wheels and axles of your Patagonia Black Hole® Wheeled Duffel.

For replacement parts or further assistance, contact Patagonia Customer Service.

Note the following when ordering:

40l and 70l Black Hole® Wheeled Duffels use 80mm wheels. 85mm wheels cannot fit.
100l and 120l Black Hole® Wheeled Duffels use 85mm wheels. 80mm wheels can fit if the 85mm are not available.
The axles, nuts and washers fit both wheel sizes.

Tools

Parts

Step 1

A headlamp is recommended for working inside the bag.
Inside the main compartment of the duffel at the bottom, locate the zipper to the liner compartment and open. This will expose the inside of the plastic wheel housing.
If the wheel and axle are missing, try and locate the washer and nut inside the liner compartment to reuse.

Step 2

If the broken wheel and axle are still attached, locate the axle nut inside the liner compartment and hold it in place with the adjustable wrench.
If there is excess foam and lining fabric blocking access, skip to Step 5 and come back.
From the outside, turn the axle using the 4mm Allen wrench to free the wheel and axle from the plastic wheel housing. Save the washer and nut to reuse.
Lefty Loosy, Righty Tighty
Test the other wheel for functionality and remove if it is broken.

Step 3

If the wheel and axle are missing, you will need to source a new wheel and axle from Patagonia. Skip to Step 5.
If the original wheel has a worn rubber tread or a flat spot, you will need to source a new wheel and axle from Patagonia. Responsibly dispose of the broken parts and skip to Step 5.
If the original wheel is in working shape, but the axle is bent, continue to Step 4.
Please contact Patagonia Customer Service for replacement wheels, axles, nuts, and washers.
40l and 70l Black Hole® Wheeled Duffels use 80mm wheels (85mm wheels cannot fit). 100l and 120l Black Hole® Wheeled Duffels use 85mm wheels (80mm wheels can fit if the 85mm are not available). The axles, nuts and washers fit both wheel sizes.

Step 4

If the original wheel is in working shape, but the axle is bent, you can often free the wheel by cutting the axle off.
Using the bolt cutters, cut the axle as close to wheel as possible.
Use safety glasses.
If the cut axle remains stuck inside the wheel, elevate the wheel with a sturdy surface, and tap the cut end of the axle using a flat head screwdriver and a hammer until the axle is driven out.
What did I just say about safety glasses?
If it is not possible to free the broken axle, you can always request a new wheel from Patagonia.

Step 5

There is often excess foam and lining fabric blocking access to the back of the plastic housing.
It is okay to cut away this excess using an X-Acto blade.
Use extreme caution to avoid cutting yourself or other parts of the duffel.

Step 6

Place a new or salvaged wheel onto a new axle and insert the axle into the plastic wheel housing.
Inside the plastic wheel housing, place a washer and a nut onto the axle and finger-turn until attached. Use the adjustable wrench to keep the nut in-place.
Tighten the axle from the outside using the 4mm Allen wrench.
Make sure the locking nylon ring on the nut engages on the axle. This prevents the nut from loosening during use.

Step 7

Do not overtighten the nut.
A perfectly-tightened Black Hole wheel spins freely for about 1-2 seconds.

Step 8

Check the liner compartment to make sure no tools have been left behind.
Close the zipper to the liner compartment.

I used a open end wrench to hold the inside nut and loosened the outside wheel, but it was a different story trying to hold the inside nut when trying to secure the new axle. I finally used a needle nose vise grip, what a difference that made. It then took me about 3 minutes to finish the repair. A needle nose plier can be used, but you have to hold it very steady to thread it, almost impossible for me. Suggest folks borrow or find a vise grip needle nose plier. It makes a heck of a difference.

Charlene Low -

Author

Zach Mueller

Member since: 23/02/23

778 Reputation

One comment

Thanks! Saved me a few emails and phone calls✨

Cullen Cole -