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How To Rebuild A Heater Valve

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I have gone through a few heater valves.  guts break, replace whole valve with another used valve, repeat.  enough.

this time i bought a rebuild kit from BLUNTTECH.  why buy a new valve when the brass part does not wear out, the kit includes EVERYTHING but the brass shell.  rebuild is a VERY simple process.


so what do you need for this job?

old valve

rebuild kit

flat blade screwdriver

phillips head screw driver

7mm wrench

small pick

brass cleaner

dremel with wire wheel


NOTE - this is just the rebuild of the later "big" heater valves and does not include the removal or install of a valve.


the kit and the broken valve



remove two screw with flat blade, take cover off.




now use 7mm wrench to unbolt control arm from back



remove broken guts



old and new guts.  new looks much stronger.



very important part here.  main reason these valve fail (at least from all the ones i have taken apart) is that the inside of the valve corrodes in one spot becoming rough.  particulary true if the valve sits in one open or closed position for a long time.  the plastic guts then hang up on the corroded area of the shell and break.


clean the inside of the brass shell until nice smooth and shiny.  i used some 600grit and a dremel wire wheel to do this, then polished with metal polish like ibis or brasso.



now assemble the guts




don't forget the o-ring on shaft



i used a little teflon grease on all the parts.







now grab the cover.  remove old o-ring with pick



same cleaning and polish rule applies to cover



install new o-ring



okay now put cover on the valve.  note the position and alignment of the guts and the arrow on the cover.



use the new screws and lock rings to assemble (new parts are phillips heads)



put the control arm back on with 7mm wrench.  don't forget the little washer.



note position of arm and open/closed valve.  we are looking at the HEATER end of the valve in these picks.








DONE!    :)

bagged up and ready for install at a later date.


Edited by mlytle
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I believe this is worthy of inclusion in the Met up in NYC.  A great DIY.  Is it archived?

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very nice indeed.  thanks for documenting this.  I've been procrastinating and am now inspired to tackle this job

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Blunt, thanks for the great rebuild kit. I want to make sure that the internal valve is a tight fit and a reasonable amount effort is required to turn the valve.

Btw, I cleaned and used superlube.


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Marshall thank you very much for documenting the process.

I disassembled the original valve and your pictures helped me assemble it correctly.



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