Introduction: How to Swap the Blade on Your Leatherman Wave, Charge, or Surge Tool

By Texas Tool Crafters Inc.
About: We modify knives, multitools and other products turning them into functional pieces of art! All of our products and materials are made in the USA!

This Instructable will give you the step by step on how to replace the blade on your Leatherman Charge, Wave, or Surge tool. The photos will follow a Leatherman Wave tool, but the steps are the same for all three tools.

Please be warned that tampering with your tool may void the warranty. If you're having an issue with your tool, Leatherman has a great warranty repair program, and in most cases you can send your tool in for factory repairs.


If you're looking for a specific modification to your tool and would like to have a warranty, please check our our website. We will mirror the original factory warranty on the functionality of all of our modified tools.

Step 1: Materials List

  • Leatherman Charge, Wave, or Surge tool that needs a new blade Replacement blade
    • Any version Charge TTi (TTi, Ti, XTi)
    • Any version Surge (black oxide, stainless, original version, new 2014 version)
    • Any post 2004 version Wave tool. If your Wave has removable screwdriver bits in it, it's post 2004.
  • 2x Torx #10 security bits or screwdrivers
    • The "security" part refers to the hole in the tip of the bit
  • 1x 1/4" bit holder screwdriver
  • Vice or clamp (for holding one of the torx bits)
  • Loctite threadlocker
    • We recommend the red strength

You can find both Damascus blades and stock blades at our webstore, txtoolcrafters.com. Here's the full list of available blades for the Wave/Charge/Surge tools:

Charge/Wave 420hc Plain Edge Blade

Charge/Wave 420hc Serrated Blade

Charge/Wave 420hc Serrated Blade (Black Oxide)

Charge/Wave s30v Plain Edge Blade

Charge/Wave Damascus Plain Edge Blade

Charge/Wave Damascus Serrated Blade

Charge/Wave s35vn Super Steel Blade

Surge 420hc Plain Edge Blade

Surge 420hc Plain Edge Blade (Black Oxide)

Surge Damascus Plain Edge Blade

Step 2: Setup Your Work Area

If you have a vice, clamp one of the torx bits firmly in place as pictured. If you don't have a vice, you can use a c-clamp or vice grips to fix the bit to the edge of a table.

Step 3: Identify the Pin and the Screw

The tool is assembled with a pin (a screw head and a shaft that extend through the tool) and a screw that attaches on the other side. For the easiest dissassembly, you'll want to hold the pin still while rotating the screw. On black oxide tools, Leatherman uses the loctite liberally and this is a MUST, not a recommended.

On your Wave or Charge tool, the pin is usually on the side with the sharp blade (plain edge or serrated), and the screw is usually on the side with the other function (saw or file).

On your Surge tool, it's usually the other way around - the screw is on the side with the sharp blade and the pin is on the side with the opposite function (scissors or file/saw).

Step 4: Remove the Screw

Take your time with this step so that you don't strip out the screw. Especially on black oxide tools, the factory applied loctite can make the screw difficult to remove.

Step 5: Remove the Pin

Use your screwdriver to push the pin out through the tool.

Notes:

  • If you are working on a Surge tool and the screw was removed from above the blade, you do not need to remove the pin.
  • If the pin does not come out easily, try pinching the blade/file together while pushing out the pin. Sometimes the file and/or blade can bind up on the pin.

Step 6: Remove the Old Blade, Check Your Bushings, and Position the New Blade

Double check that your bushings have remained in place. There should be one brass bushing under each of the functions.

If your bushings fell out of place, you can use a small drop of oil to help hold them in place while you work on getting the pin re-inserted.

Try to align everything as closely as possible. You can use your screwdriver through the hole to help center everything up.

Step 7: Re-Insert the Pin

This is the tricky step - TAKE YOUR TIME! It should not require a large amount of force to reinsert the pin. Here are some pointers:

  • You can insert the pin in either direction. If you think you might be changing the blade again in the future, it's a good idea to insert the pin so that the screw will be above the blade. This way you won't need to mess with the pin the next time you change the blade.
  • Pinch the tool on either side of the pliers (the area marked in the photo and the matching area on the opposite side) to help align the hole. There are some springs that give tension to the opening and closing of the tools that need to be compressed for an easy fit.
  • Rotate the pin as you insert.
  • Check that your bushings are aligned properly.

Step 8: Apply Loctite and Insert Screw

You only need a small amount of loctite - the dot shown in the photo is sufficient.

Tighten the screw until the desired amount of tension in the blade is reached. We recommend screwing it in until tight and then unscrewing 1/4-1/2 rotation.

Step 9: Enjoy!

Your new blade should be easy to open, but should not have wobble or play in the blade. The locking mechanism should move into place easily when the blade is in the open position.

If you're having issues you can reach us at customer.support@texastoolcrafters.com. If you purchased your replacement blade through us, we're glad to swap the blade for you at no cost (just cover the shipping).