Fixing a Sears Kenmore Water Softener

I have been struggling with the Water Softener for a few months now. I got it fixed by Sears for about 165$Cdn two years or so ago. A few months ago, it started having problems again. So I decided to try and fix it myself.

What is a water softener?

First a little background.

In North America city water is locally produced from underground water, not from a river like in Egypt. Deep under the ground there are aquifers, and the city taps into it, treats it and make it available to the inhabitants. If the bedrock has a lot of calcium, .e.g limestone, in it, then the water is often said to be "hard water".

Hard water causes a lot of problems: dishes would look cloudy, the tea kettle will have white residue in it, soap will not rinse from your hand (no squeaky clean feeling), your hair will clump if you use soap in the shower instead of shampoo, and the water heater efficiency will decrease as the calcium from the hot water precipitates on its walls. Soap and detergent use is also increased.

How does a water softener work?

So, there is a market for water softeners in places that have hard water.

A water softener works by having a tank that is filled with salt, and a tanks full of a special resin. The resin can remove the hardness from the water, but requires that it be regenerated by washing it with salt brine during regeneration. Water softener are either demand based (after a certain number of gallons have been processed), or time based (e.g. twice week). Regeneration happens in the early hours of the morning, depending on how you set it. It goes through several cycles, which are basically:

  • Fill: Water is passed to the salt tank
  • Brining: Water is left in the tank to form brine
  • Rinse: The brine is used to rinse the resin, remove the calcium that it has removed in the past, and make it able to remove calcium again
  • Back Wash: The resin tank is flushed for residues and iron deposit
  • Fast Rinse: The resin is rinsed from all the above
  • Service: This means that the water softener is serving soft water for the house

There are many brands of water softeners out there in the market. Many are rebranded. For example, Sears Kenmore, Ecoline and General Electric (GE) are the same. Culligan is also similar.

About my handyman's skills

Before I start, I should say that I am not at all handy with maintaining a house. Part of it is due to the fact that in Egypt most people live in concrete apartments, and not woodframe and drywall houses with lawns. Part of it is that I never got the hang of being mechanically adept, whether it is plumbing, carpentry, car maintenance, and such. So, fixing a water softener, which involves mechanical, electrical and plumbing aspects is quite a challenge.


Many things can go wrong with a water softener. The basic complaint is that "there is no soft water". Another is high water level in the salt tank. Yet another is salt level that does not go down as the weeks pass.


The manual for a water softener often has some comprehensive diagnostics that can be done to see

Start with cleaning the nozzle and Venturi. This should not require any tools, and can be disassembled and assembled by hand. Take note on how things fit before you remove them. Wash the components in water. Use some vinegar. Make sure there is no deposits, salt, rust, calcium or debris.

Then check the float in the salt well in the tank. The float should be able to move up and down, and the hose should be able to inject water in the tank and suck it again.

Then shut the water supply, drain the house (open the lowest lying faucet in the house), then disassemble the cam gear and rotor from the valve head. Check all the seals and gaskets and that there is no wear on the smooth side of the rotor.

Run the diagnostics as per the manual, and make sure that the cam gear moves well. If the motor is skipping and making a clicking sound and failing to move the cam gear, then replace it.

Replacing all the gaskets, the rotor, the cam gear and the motor should solve most problems, and only cost me 74$ Cdn. That is provided that the nozzle/venturi are clean, and that there is no obstruction to the float assembly.

Check for the formation of a salt bridge, specially in humid environment. Tap the side of the tank and see if there is a hollow sound at some spot under a solid sound. Use a broom stick to break it.

Once every six months, get a water softener cleaner (basically a sulphite powder that removes iron deposit. You can buy it at Canadian Tire or other hardware stores. It is more expensive at Sears, so avoid buying it there.

Every year or 18 months, try to remove all the salt from the tank and wash it. You can use warm water, and a wet/dry vacuum to remove it.


Fixing a water softener is easier than you think. Save your money and do it yourself. Get the manuals online, go buy the parts, and do it.

The morale of the story is: If I could do it, anyone can do it.

Resources and Links

Here are some useful links with more information:



Water in tank

I just had this problem occur this morning with water in my tank. I shut down the unit and drained all the water out. 95% of the salt dissolved. Took a flashlight to see what was going on. Turned the water back on and noticed a 1" long crack in my fibreglass tank. The unit is less than five years old. As I looked closer, it looks like a 6" stress crack was forming.

I am now looking to either replace the tank or buy a new unit. Cost benefit will follow and I'll respond back to those who are interested.

Unfortunately, I did not have a hose hooked to the 3/8" top drain and it leaked all over the basement. Fortunately, I don't have a finished basement. If you have a unit, invest in 8-10' of hose and drain it to a sump or floor drain.

what series is my kenmore

what series is my kenmore demand water softner if the model number is #625.348491

Where to get Kenmore Genius

Where to get Kenmore Genius Water Softener Mod.# 625.75830 manual?

Brim tank full of water

Brim tank is full of water and runs over at times.

Brim tank

I am having the same problem, I am going to try the troubleshooting to see if I can fix it, Does any one have a solution?

old sears softener

we have an old sears softener that was on a house that had sat vacant for years, it was disconnected and we don't know if it worked, it is a 1978 model 625.342701 Sears does not have a manual available from their parts dept and I can't find one online. Does anyone know where we might get one to be able to see if we can salvage this unit? Thanks!

Old sears softener

I have the same softener in the house I just purchased and it hasn't been run in years either. I was wondering how you made out.

Kenmore water softner 2 yrs old

I recently replaced pressure switch on supply line from well, since then have had heavy salt taaste on the hot water side of the system. Could you tell me how to correct this.
Thank you
Bill Van Riper


I have a GE water softner for 3 yrs now..On the 4th of July it started to leak from the inlet on the bypass valve.. I replaced the o-rings and the clips on the outlet and inlet.. Aslo made sure the it was level,but I still get a leak on the inlet side. I can see nothing wrong with the bypasss valve or control head. I need suggestions on how to stop the leak..

Replace the bypass valve &

Replace the bypass valve & it should take care of the problem (leak) .