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 softener leak a input

i am having a similar problem with my softener. did you ever find a fix to your leak issue?

bypass valve leaking (dripping)

I had EXACTLY the same problem. The bypass valve was dripping slowly at the inlet. I tried changing o-rings, cleaning etc., nothing worked. The valve looked like new. I went on-line and ordered a new bypass valve from the sears WEB site. That solved the problem. It hasn't leaked since. I still don't have any idea what was wrong with the old one.


I have a two yr old Kenmore in a house I lease out. When I'm at the house and trial run the softner it works fine.
Next thing I know I get a call saying there is a slushy salt mix on the floor that is firm enough to be picked up with a shovel.
I would appreciate any suggestions!

Model 625.3485500 #1 Select

Model 625.3485500 #1 Select button does not function when I push it.

Laundry not clean with Water Softner

We have had a water softner system for over a year in our house and we have used several types of luandy detergent when washing our clothes. Our clothes are never clean. After one use, our towels are just as stinky as before we washed them. Many time the clothes smell like they were not washed at all. Has anybody else had this problem? General Electric says that there is nothing wrong with their system.

Same problem.

We have the same problem. Did you ever find your answer to why this was happening?

Very salty water in morning only

Our Kenmore water softener is about 2 years old and just recently we began to experience a very salty taste until some water is used in the morning (usually taking a shower) and then everything is fine until the following morning. Any suggestions please?



salty water

i think you should not use so much salt in your softener....if your water is salty that says to me your using to much salt....cut your salt in half and see if that makes a change in about a takes about a little less than a week to take hard water and make it not hard so i think it'll will work the other way in reverse....worth a try.......that's what i'd do first....after that i'd take the ventury out and clean that 100%....,,,you might also bang the side of the water softener easily because you may have a slight clog at the sides of the water softener....these are a few things you can do....but i'm sure you can solve the problem....just don't get to in a hurry and do them one at a time....remember rome wasn't built in a daymay take a couple weeks to try them all but heck we all got time....

Salty Water in the Morning PLEASE HELP

We are having the same problem. Cleaned the venturi. No salt bridge.
We find it strange that it only happens in the morning at kitchen faucet only. After running the water for approx. 2 minutes the salty taste goes away.
Any suggestions will be greatly appreciated!