Safety: Disconnect power before removing the valve cover. Avoid placing fingers near moving gears when testing.

Steps:

Remove cover and inspect: Take off the Clack valve cover and visually inspect the cam gear and drive motor while manually advancing the cycle (with power off).
Check for broken teeth: Look for missing or damaged teeth on the cam gear. Replace the Clack cam gear assembly if any damage is found.
Verify motor mounting: Ensure the drive motor is securely fastened and not vibrating excessively. Tighten mounting screws.
Inspect piston bore: Remove the piston and seal pack and check for debris or scoring that could cause binding and noise. Clean the bore and replace the piston and seal kit if worn.
Test operation: Reassemble, restore power, and run a manual regeneration while listening for noise. If noise persists, the drive motor itself may be failing and should be replaced.

Note: Some clicking is normal as the cam advances, but loud grinding or knocking indicates a mechanical fault.

Clack water softener makes loud clicking, grinding, or knocking noises during regeneration.

Possible Causes