DU640XTKQ0 Whirlpool Dishwasher - Instructions

The repair was similar to the very good video provided by PartSelect. However, I did make a few changes. The new rack was slightly different in the front side compared to the old rusted rack. After I removed the old rack from the dishwasher, I placed the two racks side-by -side to make sure they were compatible. They were identical in the rear structure and overall size, so I proceeded to change out the wheel racks, rack height adjusters and upper wash arm to the new rack. I suggest transferring each part one at a time so you can get the spacing correct. Also, in my case, many of the items needed to be washed with water to remove soap buildup in these parts before moving to the new rack. I would also suggest putting the upper wash arm (needed in this case) on the new rack last. The total job took me about an hour including washing or rinsing all parts and reassembly. This is an easy job, just take your time and do one item at a time so nothing gets mixed up. I used a drill driver to remove a total of 4 Phillip head screws for the rack height adjusters but a regular Phillip head screw driver would work as well.

This is the second time I have replaced a rack. You just pop on the new rollers and you're good to go!

Disconnected the damaged hose extension from the dishwasher outlet drain hose and the connection to the sink drain. Removed two clamps. One a spring clamp and the other a screw clamps. Connected the new extension hose with a spring clamp to the dishwasher outlet drain hose. Connected the other end to the sink drain with a screw clamp. Checked for leaks. Good to go!

Turned off water supply. Then removed water supply line, secondary hose, and screw securing inlet valve. Valve will slide out. Removed brass elbow fitting from old valve. Applied plumbers putty to threads on both ends of elbow and attached to new valve. Installed new valve and secured with screw. Re-attached hose and supply line. Turned water supply back on and checked for leaks.

From searching the partselect site, I was able to determine that the fuse was most likely the faulty part, and probing the voltage confirmed it. So I ordered the Fuse Kit.
I was very pleased with the level of diagnostic information available on partselect.com.

The kit instructions were clear. With power off, I removed the old fuse, clipped the existing wires, stripped them, and reattached to the new wire connector. Then I snapped the new fuse in place and put the cover panel back on. Everything works fine again and my wife was very pleased.

No brainer.. the correct part was shipped and the Mrs is now happy

We took the rollers off the old one (new ones came with the dishrack also) and put them on the dishrack (they snapped on). There was also an extra piece that we figured out how to put on. Then slid it in place and it was fine.

Repair was a "no brainer". Pulled out the old gasket, started the replacement of the new gasket in the lower right hand corner and worked all the way around the opening, then trimmed excess gasket of about 2" with a pair of scissors and I was done. Total time - less than 5 minutes.

I opened the dishwasher door, removed the old tired seal in a manner of seconds. I measured the old seal against the new, same length, so no cutting. I started on one side pushing the seal in to the groove, made sure the seal was centered in the door. (not too long on one side or the other) It took less than 5 minutes to place the seal and check that it was all the way in, all around the door. I wiped the door down with some cleaner, where it contacts the seal. The door was harder to close, but I expected that until it breaks in. I ran a short load in the dishwasher with no leaks. :)

First, I turned the power off at the circuit breaker.
Next, removed six screws securing front panel to the dishwasher. Then, disconnected power supply to the dispenser. Followed by unscrewing the four screws that held dispenser in place. Easily removed unit and replaced with new dispenser. Secured in place with screws, then connected power supply. Then, fastened front panel and turned circuit breaker back on.
Viola! New dispenser is working like a charm!

After looking at what everyone else had done, I decide that I would take the dishwasher out of the wall space and set it on its side. This require me to turn off the power first. Then I pull the diswasher out from its space in the wall. I turned off the the water and then took off the water hose, then took of the return hose. There was water left in both, so there was a little water on the floor as a result of this. Then I finally pulled out the unit and laid it down on its side. The motor was very visible and was easy to access. The hardest part was finding the bolt to take it off. I pulled off the power connector to the motor and then took off the one bolt that was holding the motor on the washer. Then I twisted the motor, but it would not come off. I finally got a screw driver and put it in the small opening between the motor and the connection and it finally came off. This took all of about 30 minutes. Once I got the motor off, I notice that the aluminum grating inside was dirty and needed cleaning. So I cleaned this and put it back inside. The new motor came with every thing, so I put it in and twisted it. Then put back in the bolt, reconnected the power cable, put back on the water and reconnected the output cable. In order to make sure there were no leaks before I put it back in for good, I ran a short wash to check to see if everything was tight. There were no leaks, so I put everything back in the wall. It really did sound very nice now. This dishwasher unit came with noise padding, so I put that back as well. The dishwasher, now is very quite and I don't mind it running any time during the day. The hardest part about this is getting the motor off and find the bolt. It is down between motor and the unit and there was some aluminum between this and the dishwasher, so you need a long nutdriver to get it off.

I had to remove the baskets, spray assemblies (no tools needed) and disassemble the section of the pump that contained the chopper assembly. (removing three Torx screws)
I had to remove a part of the old chopper that had gone into the pump, but I was lucky that a magnet grabbed it so I didn't have to disassemble the pump.
The total repair was not difficult. The only problem was access (hands in the way while repairing difficult to see) and compressing the spring on the new chopper while trying to slip it into the groove.
The parts came in three days and they fit perfectly

I decided to proceed with repairing the dishwasher myself even though it's 18 years old and this is the first problem we've had with it. This dishwasher has worked amazingly well and matches our kitchen.
I found the Partselect website to be very easy to navigate and very happy that it had parts for my dishwasher model along with troubleshooting tips, reviews and installation videos.
I started with replacing the door gasket as it seemed quite compressed and missing part of one end. The part came quickly in just 2 days. It was an easy installation. Unfortunately, it did not fix the leak.
Next step was to turn on the dishwasher and slide my cell phone further underneath with the video on to try and catch the culprit. Water was dripping off several points but it appeared that the leak was from two or three places around the main tub bottom gasket. That gasket is not available as a separate part. so I had to order the whole pump and motor assembly. Again, the part came in two days.
This part was a bit more challenging to replace. The installation video was very helpful. I removed the old part easily. I thoroughly cleaned the gasket seat area and added a layer of silicon grease. While rubbing on the grease, I found a few corrosion pinholes in the bottom of the stainless steel gasket seat. I did not feel that they were significant enough to worry about since the new gasket should easily seal them. I turned out to be right. The biggest challenge was reinstalling the motor assembly clips. They were very tight but I eventually got them all in with the help of a small mallet.
Once reassembled, I tested the new motor assembly by just pouring water into the bottom of the dishwasher, and not turning it on. There was still a small leak further to the back of the motor assembly. Using my phone's video, I could see that the tub gasket was no longer leaking, but the Thermistor sensor was.
I could easily remove the sensor by twisting and pulling it off. The sensor was in good shape. I figured that it must be the o-ring around the sensor casuing the leak as it appeared somewhat compressed. Unfortunately, the o-ring is not sold separately from Partselect. Therefore, I took the sensor and o-ring to the local hardware store where I was able to identify a replacement o-ring for one dollar.
I reinstalled the sensor with the new o-ring and water tested again the dishwasher. No more leaks!
I ran a wash cycle and still no leaks! We have now ran several dozen cycles without any leaks. All is good! It appears that I definitely had leaks around the the main tub bottom gasket as well as the Thermistor sensor. After eighteen years of use, I feel it was still a good idea to replace the door gasket even though I could not fully verify that it was a problem.
We are now able to keep our dishwasher (hopefully for many more years) and saved significantly by doing it myself.

The repair was overall a simple one. The only difficulty I had was in seating the new motor assembly in the dishwasher bottom opening. I tried doing this with the dishwasher on its back after I made my disconnections and pulled the old assembly out; but with fighting the spring action of the door while trying to seat the seal it was a pain. It's definitely worth uprighting the dishwasher again to seat the new motor as you no longer have to fight the dishwasher door and you can get in with both hands to overcome the seal friction. I used silicone lube but that seal is still pretty tough. Although there was nothing wrong with it I changed the water supply hose as well just as a precaution as my unit was 12 years old.

Turned off the power at the breaker, turned off the water supply, disconnected the water line, removed all three racks, pulled dishwasher out from under the counter, laid the unit on its back, removed the flat plastic water lines from inside the dishwasher, disconnected the hose and all wires (plugs) that were attached to the motor & pump assembly, removed three plastic wedges that held the pump assembly to the bottom of the dishwasher, tried to remove the motor & pump assembly from the inside of the dishwasher but it wouldn't fit through the hole, removed two parts from the motor a silver cylinder with two wires attached to it and a white plastic piece with copper wound wires and magnets in it so that it would fit, once the entire assembly was out removed one screw that holds the motor to the plastic pump assembly, twisted the motor counter clockwise the pulled it straight off, after installing the new motor I removed the silver cylinder (maybe a capacitor) that was attached to the motor leaving the two wires attached to it so that the assembly would fit through the hole in the bottom of the dishwasher, cleaned the rim of the hole and the rubber gasket on the assembly, put the assembly through the hole in the bottom of the dishwasher, installed the three wedges to hold it in place, then put it all back together. When I ran the dishwasher it was as quiet as when it was new.