Kohler Kitchen Faucet Repair in 10 Steps

 

Repairing Kitchen Faucet, Model 10416 (Updated)

 

Kohler products are built to last a lifetime, but like any mechanical device, occasional maintenance may be necessary.  Some common problems you may encounter with your kitchen faucet 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, find the model number (P/N number) of your fixture, which is located on a tag attached to the faucet’s cold water supply line.    Because Kohler parts have a lifetime warranty, they will be replaced for free by contacting Kohler’s Customer Care Center at 1-800-456-4537 or by visiting 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 (If you are not having problems with flow fluctuation from the handheld sprayer, you will not need this part.)

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
  • 1 1/16″ Open Wrench (or adjustable wrench that will open to this size
  • Channel Lock
  • Hammer
  • Wide Blade Screw Driver (non-metallic if you have one)
  • Small Screw Driver (or knife-edged device)
  • Needle-Nose Pliers
  • Paper Towels
  • Old Wash Cloth or other heavy 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 not sure which valves belong to the faucet, you can turn off all the valves.

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 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 by grasping tightly with your hand and twisting off. 

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 up freely, but don’t be afraid to give it a good upward jerk.  If it still does not move, you may need to position 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 (optional step, only necessary if the Faucet Diverter needs to be replaced)

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 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 1 1/16” open end wrench (or crescent wrench) to  remove 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 top cover.  If the faucet body slips in your hand, place a washcloth around the body and use a channel lock to keep it from spinning as you remove the top cover. 

When you’ve loosened the cover, 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 cover. Securely tighten it with the 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. Don’t forget to turn the water supply back on.

Below is a visual guide of the repair.

Is There Still a Leak Under the Sink?

If there are still leaks under your sink when you turn on the faucet, the end of the plastic connector (see below photo) may have deteriorated, causing the spray handle/hose assembly to develop a leak.  A simple test to confirm that this is the problem, is to pull out the sprayer, turn on the faucet, and watch for leaks around the base of the sprayer. If there are leaks, then you will need to repair the sprayer/hose assembly, as shown below.

1 Photo

Step #1: Order Replacement Part

Contact Kohler, and order the sprayer/hose assembly.   Identify the finish of the sprayer to make sure your replacement matches your faucet.

So that you can continue to use your faucet while the replacement part is in transit, pull out the sprayer and leave it in the sink. By doing this, any leaks from the sprayer will go down the drain instead of leaking onto the floor under your sink.

Step #2: Replace the Spray/Hose Assembly

Disconnect the hose under the sink, which may not be very easy.  However, persistence will eventually pay off.   A 15 mm flare-end wrench will fit the nut holding the hose to the bottom of faucet.  When it has been disconnected, remove the hose and replace it with the new assembly, and re-tighten.

2 Photo