AO Smith Mechanical Drive Noise / Gear Damage

Softener makes loud clicking, grinding, or knocking noises during regeneration.

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Safety Warning

This repair may involve working with high voltage components or water connections. Always unplug the appliance before removing any panels.

If you are not confident in your ability to perform this repair safely, we strongly recommend contacting a professional technician.

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Possible Causes

Worn or stripped drive gears, Misaligned cam, Debris in valve causing hard spots, Failing drive motor

How to Fix / Troubleshooting

Safety first: Unplug the unit before removing the cover.

Observe during regeneration:

  • Start a manual regeneration and listen closely to identify when the noise occurs (e.g., during position changes only or throughout the cycle).

Inspect drive components:

  • Remove the cover and visually inspect the drive motor and gear train.
  • Look for cracked or missing gear teeth, loose mounting screws, or a warped cam.
  • Check that the motor is firmly attached and not vibrating excessively.

Replace the drive motor assembly or gear kit if gears are damaged or the motor is noisy. If debris in the valve is causing binding, the valve head may need to be disassembled and cleaned.

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Repair Difficulty

Hard 4/5

Required Part

Drive Motor Assembly
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