I had the same problem. The Hub One was delivered with an extremely over torqued quick release adapter. When trying to remove it with the included tool, it got damaged.
I went to my local bike shop and even they had a hard time removing it, using special tools .
But in the end they succeeded and charged me nothing. Very happy now, but not a great start using Zwift.
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I have the same problem, and I donât know how to remove the hub. So the solution is not clear to me
To remove the cassette you will need a chain whip and a cassette lockring tool. Most bicycle parts suppliers sell these tools. There are inexpensive kits that contain both tools. You can also take it to a bike shop if you donât want to buy the tools.
https://support.zwift.com/en_us/removing-a-cassette-from-your-zwift-hub-BkBX2TIki
Thank you for your reply, but would the procedure be the same for the cassette and the hub? I have the Zwift Hub One.
Yes the cog on the Hub One is just a cassette like any other. The only difference is that the torque specification for the lockring is lower than for a normal cassette. You even have the option of installing a normal cassette on the freehub if you want (for example if you want to use it with something other than Zwift).
Having the same issues with my Hub One, that has been delivered today. No chance of removing the quick release adapter. I completely wrecked the adapter and cannot get if off. Also contacted customer support and now wait for their response.
Thatâs a good bike shop 
Glad to hear they got you squared away.
It is not destroyed. A bike shop could get it off and clean it up with a file. Itâs certainly unfortunate that you were put in this position. Itâs especially disappointing given how long this assembly error has been going on.
One guy in the factory with a poorly calibrated air wrench. I swear sometimes it comes down to something like that.
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hi. got mine today and same problem. going to try with the local bike shop
back again 2 minutes later because as a last attempt I managed to get it off! I used a good quality vice grip but rather than tighten it flat to flat on the nut, I tightened it on a 45 degree angle so whatever corner was left on the nut was inside the gripâs teeth.
then I prayedâŚ
and it came off!
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Same for me, mine arrived overtightened and was impossible to remove. A pretty bad first experience with Zwift, why has this not been rectified already?
Hello.
Same problem here with the Zwift Hub One that I hot yesterday. No space at all to use the tool (50% of the nut surface is accesible and the other hidden) and no way to release the nut, making effort will only cause the nut to get rounded. Also tried with pliers wrench and no effect, nut is totally stuck.
I am sharing the problem with @Ride_Cyclery customer service but no useful help receivedâŚ
Any clue about how to proced? Thanks in adcance.
Would you be able to access that nut better if you removed the hub first (or even just the cassette ring)?
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Itâs mind-boggling that new trainers are still being sent out with this long-standing issue. Not a great first experience for many users.
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Remove the cassette before you try to get the adapter off.
Not sure how that applies to the Zwift cog.
Itâs a cassette with one cog on it. Removal process is the same as any cassette.
@Daniel_Weeden if you can remove the cassette lockring, you can then remove the Zwift cog, which will give you complete purchase on the flats of the QR adapter⌠Also, just the removal of the lockring would give you a bit more access to the flats, even if you just left the Zwift Cog in place. Depending on how tight the lock ring is, you may not need the chain whip, but you need to be able to hold the cog tight enough that you can remove the lockring without spinning the freehub (possibly with your hands or a rubber strap wrench if you have one). When you tighten the lockring, you donât need a chain whip, just for removal.
It seems to me the Zwift Hub One should possibly include an inexpensive lock ring removal tool given the prevalence of this issue but alas, they do not.