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Repairing Kitchen Faucet, Model 10416

Kohler products may be built to last a lifetime, but like any mechanical device, periodic maintenance is sometimes needed. Common problems are leaking around the base of the faucet, sporadic disruption in the water flow when initially turning on the faucet, and low water flow from the hand held sprayer. Fortunately, in only an hour, you can make the necessary repairs yourself.

First, you need to locate the model number of your fixture. Under the sink, there should be a tag attached to the faucet’s cold water supply line. There will be a P/N number printed on the tag, which is the model number. Because Kohler parts have a lifetime warranty, they will replace parts for free. Contact Kohler’s Customer Care Center by calling 1-800-456-4537 or at this Internet address. You should receive the parts by mail within a week to ten days. Here’s a list of parts you’ll need:

  • O-Ring Faucet Repair Kit – Item GP30420
  • Single Control Valve (Valve Cartridge) – Item GP75878
  • Diverter Assembly – Item GP1016515

Now, follow these steps to a like-new kitchen faucet.

Step #1: Before Beginning Faucet Repair

Collect the tools and supplies you’ll need before beginning your repair project. This will make the process much easier, less frustrating, and you’ll complete the repair a lot faster. Here’s what you’ll need:

  • 1/8″ Allen Wrench
  • 3/8″ Box or Open End Wrench
  • 8″ Minimum Crescent Wrench
  • Hammer
  • Wide Blade Screw Driver
  • Small Screw Driver (~5″ long)
  • Needle-Nose Pliers
  • Paper Towels or Cloth
  • Mild Cleaning Product
  • Something to Cover Sink Drain(s)
  • Portable Light

Turn off the hot and cold water supplies. If you have a dishwasher or ice maker, there may be more than two valves under the sink. If you’re uncertain which valves are for the faucet, you can turn off all of them, but don’t forget to turn them on again after the repair is complete.

Cover the sink drain(s), so parts don’t fall into them.

Step #2: Remove Faucet Plug Button

The plug button is a small oval button in the back of the faucet handle. With the handle in the up position, pull the button out. If it isn’t easily removed, place the tip of a small screwdriver underneath the faucet handle skirt, which is directly behind the plug button, and push out. Remove the button with a thin prying device (or your fingernail).

Step #3: Remove Faucet Handle and Bonnet

Remove the set screw, which is located inside the plug button opening. With the handle still in the up position, insert the Allen Wrench in the opening. If you don’t see the screw, position the wrench perpendicular to the vertical axis. Once the screw is loosened, so that it’s no longer making contact with the hub assembly, remove the handle. Next, unscrew the bonnet, which is located above the hub assembly.

Step #4: Remove Faucet Hub Assembly

Remove the hub assembly by pulling it up and over the body of the faucet. After years of operation, mineral buildup may prevent the assembly from moving freely, so you might need to remove it by positioning a wide-blade screwdriver between the sink and the assembly. Gently pry up, until the assembly loosens from the sink. Be careful not to scratch the surface of the sink or hub assembly. If you use a non-metallic screwdriver, you can avoid scratching the surfaces.

Step #5: Replace Faucet Diverter

The Diverter is a small circular assembly located in the back of the faucet. If you are unable to pull it out with your fingers, remove it with the needle-nose pliers. Push the new Diverter, fins pointing out, into place with your fingers.

Step #6: Replace Faucet Control Valve Cartridge

To get to the control valve cartridge, use the crescent wrench to loosen the large hex nut cover at the top of the faucet body. Hold the faucet body with your hand to keep it from turning while “wrenching off” the cover. If it isn’t coming loose, tap the handle of the wrench with a hammer. It would be helpful to have an extra set of hands to hold the wrench in place while tapping it.

Once the hex nut cover has loosened, fully unscrew it to remove it. Note the position of the cartridge’s opening, relative to the sink, and then remove the control valve cartridge. If the gasket on the bottom of the valve cartridge remains in the faucet body, be sure to remove it before reinstalling the new valve cartridge.

Wipe out the faucet body and install the new valve cartridge, being sure it is properly oriented. To do this, align the dowels on the bottom of the valve cartridge with the holes in the faucet body. When the valve cartridge is in position, screw on the hex cover. Securely tighten it with the crescent wrench.

Step #7: Replace Faucet Seals

Remove the two o-rings and two bearings, which are located at the top and bottom of the faucet body. Wipe down the entire outer surface of the faucet body to remove loose debris before replacing o-rings and bearings. Apply the silicon lubricant that was provided with the Kohler replacement parts to the o-rings. Replace the o-rings and the bearings in the order they were removed.

Step #8: Replace Faucet Hub Assembly

With the o-rings lubricated, the hub assembly should easily slide back into place.

Step #9: Replace Faucet Bonnet and Handle

Screw the bonnet back into place. Then, put the handle back on, tightening the set screw and replacing the plug button.

Step #10: Tighten Bracket Under the Sink

If the faucet assembly has loosened from the sink during the repair, tighten the bracket under the sink. Congratulations – you’ve just finished repairing your Kohler kitchen faucet.

Finishing Up

All that remains to be done is putting away your repair tools, discarding old parts, and cleaning your sink and reassembled faucet. Also, remember to turn the water supply back on.

Below is a visual guide of the repair.