Fixing a Direct Drive Washing Machine

How to repair a dead washing machine by replacing the direct drive coupler.

Step 1 Starting the Project

Washing machines seem to last for years, but when they break you quickly realize how much you depend on them. Our ten year old machine died on Saturday, and with the poopy kid's pants piling up I knew something needed to happen quickly. The Sears repair man couldn't make it out for at least a week and wanted 75 bucks just to show up. Luckily, I had internet access and the delusion that I could fix my own stuff.

Our machine would fill with water, make noises for a while without moving, then drain and repeat. Because the same motor that pumps water out of the tub runs the agitator and spin cycle, I knew that the motor was working but that the link between the motor and tub had been lost. In older belt drive machines this is usually a sign of a broken or loose belt, in direct drive machines like mine it's a broken motor coupling.


The motor coupling is a collection of plastic and rubber parts between the motor and the transmission who's job it is to fail before any damage is done to a more expensive part. It works like a circuit breaker, shutting down operations before the motor seizes. We had over stressed this part with some big blankets and towels, now it needed to be replaced.

Comments

[Phil B]

Our 15 year old Sears direct drive machine stopped working on the spin cycle. I began checking appliance repair web sites. This coupler was not the problem. First, the timer's contact points for the spin cycle were completely burned away. A new timer helped for a few loads, but then the machine began to show its age in other areas. I found there are half-of-a-dozen different reasons why one of these washers may not work on the spin cycle: dragging brake shoes, worn or broken tabs connecting the transmission shaft to the tub, problems inside the transmission, broken or worn clutch, and probably one or two more. As best I can tell, ours failed because of a worn pawl inside the transmission. Gears for the transmission are available, but other transmission parts are not. New transmissions are available, but the cost is too much compared to the cost of a new machine. Some will need to remove the tub nut, and that can be difficult. I did just publish an Instructable on removing the tub nut.

[texascal]

You don't need to remove the cabinet. All you need to do is lay it on its back and access the motor through the bottom. I have the same model and it was a quick thirty minute job, without disassembling the entire machine.

[SierraTwoOne]

you are correct about not having to remove the cabinet, but it does make it easier to do the job if you do.  some laundry rooms do not have enough room to lay the unit on it's back.  I've seen units jammed in a closet in a hallway where I being an experienced technician has a hard time doing this job.   Mobile homes are the worst for space. 

[SierraTwoOne]

Nice instructable.  I am a repair man for a small company, and I do about 3 of these a week!  and you're right about the $150. Service call, part, and labor are usually some where close to that.   A Normal homeowner will probably  take about an hour too do this repair while following this Ible.  With practice you can get it down to about 15 minuets. 

[wmc]

I have the coupling replaced and motor back on with top bracket attached. I can't get the bottom bracket to snap in place - any suggestions?

[jdean2000]

Check to make sure that the bracket is seated correctly on the other end. Also, make sure the coupling parts are pressed down far enough on the motor axle.

[HALABOUTIT]

IMPORTANT :---Replace the cabinet---. Look at the base of the washer on the sides. You will see two extrusions or metal tabs that mate with slots in the bottom of the cabinet. The cabinet has a lip on the bottom front that goes under the bottom frame of the washer. Place the lip under the base, let the cabinet down to mate to the extrusions on the base. Line the back up to the cabinet and replace the brass colored clips that hold the back of the washer to the cabinet. Plug the lid switch back in. Put console back in place and install the screws holding console. MAKE SURE THE FRONT OF CABINET IS UNDER THE LIP!!!

[HALABOUTIT]

Mark any single wires outside of wiring harness. I had three separate wires attached to other gizmos and experience taught me to record what goes where when putting the wires back on.

[HALABOUTIT]

I used a 1/2" drive extension (6") to tap on the gears. The 1/2" socket on the extension did not work well for me. Also, spend a little time cleaning up old black rubber material on shafts and housings before installing gears.

[HALABOUTIT]

Two people can make this step go a lot smoother. both sides need to align properly, hence a person to each side.

[HALABOUTIT]

I just set the gear hole edge flush to front edge of shaft. If someone knows a better alingment, please post.

[HALABOUTIT]

I put some blocks under the front of the cabinent frame which tilted the unit backwards and off the floor. This made for easier acess. You need to do it properly so it won't slip off when tapping on coupling gears.

[HALABOUTIT]

You may not need to remove the pump. I left the pump attached to the motor and was able to move the pump/motor assembly out of the way together. If there are any other wires attached to the motor assembly besides the main harness, such as a condensor on the side as with my Kitchen-Aid, mark them as to what goes where. (top/bottom or left/right)

[HALABOUTIT]

You may not need to remove the pump. I left the pump attached to the motor and was able to move the pump/motor assembly out of the way together. If there are any other wires attached to the motor assembly besides the main harness, such as a condensor on the side as with my Kitchen-Aid, mark them as to what goes where. (top/bottom or left/right)

[compnerd4]

OMG... OK I have the exact same washer and i broke today so i lugged it out sided when to my computer to look for a new one. My home page is "igoogle" and i have the Instructables tab and it was the same problem. Thank a lot for and excellent Instructable!!!