If you have a gas-fueled Bradford White hot water heater and your pilot light won’t stay lit, chances are you have a broken or failed thermocouple. This component is essential for the operation of your water heater, and replacing it is a straightforward process that can do it by yourself and save money on technician fees. So, in this article, our water heater expert Joseph will explain in step by step process on how to replace your Bradford White water heater Thermocouple.
Identifying and Choosing a Replacement Thermocouple
First look for the heater model and look for the part number if you can and you can purchase replacement thermocouples online at stores like Amazon or any offline stores. Common sizes include 24-inch and 18-inch thermocouples, but it’s always better to choose the longer one and coil the excess length during installation. Ensure the replacement thermocouple matches your water heater’s specifications for compatibility. To know how old your water heater is? check or post Find Bradford White water heater Age by Serial number.
- Link to buy the thermocouple: https://amzn.to/3CXwMhg
- Honeywell Resideo Universal 24 inch Thermocouple: https://amzn.to/4fMr5l4
Steps to Replace a Thermocouple
Preparation
- Turn Off the Gas Supply: Locate the gas supply valve and shut it off to ensure safety while working.
- Remove the Bottom Plate: Take off the bottom plate concealing the burner assembly to access the internal components.
Accessing the Thermocouple
- Disconnect Connections: Detach the thermocouple, igniter wire, pilot tubing, high temperature cutoff wires, and main burner supply connections. With the help of a crescent wrench you can loosen the compression nuts.
- Remove the Burner Assembly: Unscrew the screws holding the burner assembly in place and slide it out. This also allows you to clean debris for better flame quality and burn patterns.
Removing the Old Thermocouple
- Detach the Thermocouple: Remove the old thermocouple from the pilot assembly. Pinch the clips or use pliers to release it from the mounting bracket.
- Check the Push-Fit Adapter: If the old push-fit adapter is not compatible with the new thermocouple, replace it with the one provided.
Installing the New Thermocouple
- Position the New Thermocouple: Slide the new thermocouple into place. Ensure the tip is positioned correctly in the pilot light’s flame for proper operation. The brass clip should hold the thermocouple securely in place.
- Reassemble the Burner: Reinstall the burner assembly, ensuring all components are in their original positions. Reconnect the pilot tubing, thermocouple, and igniter wire, tightening them by hand first to avoid stripping threads.
Testing and Final Steps
Relighting the Pilot
- Turn On the Gas Supply: Restore the gas supply to the water heater and relight the pilot. If you’re unsure how to light the pilot, check our detailed post: How to light a pilot light on a water heater. Hold the pilot button down long enough for the thermocouple to heat up and send the proper signal.
- Check for Gas Leaks: Use a soapy water solution to test for leaks. Paint the solution onto the connections, and check for multiplying bubbles. If you notice any, turn off the gas and tighten the connections further and check again until you see no bubbles.
Testing the Main Burner
- Ignite the Main Burner: Remove the vacation mode and set the gas to the desired level between WARM to HOT. Verify that the pilot and main burner function correctly. The thermocouple should remain in the flame to maintain the signal for safe operation.
Final Reassembly
- Replace the Covers: Reinstall the burner door and debris shield. Secure all screws and ensure everything is tightly fastened.
Key Tips
- Always ensure the thermocouple is in direct contact with the flame.
- Do not crimp or treat the thermocouple harshly, as it’s a delicate component.
- Cleaning debris during replacement ensures optimal burner performance.
- This job typically takes 15–20 minutes and costs around $20 for the part, saving hundreds compared to hiring a technician.
If your water heater pilot fails to stay lit, replacing the thermocouple is a simple fix. With proper care and safety measures, you can restore your water heater’s functionality with minimal effort.
Got a quote for $380 to repair my thermocouple. Noticed they were less than $10 on Amazon. After reading this I thought it didn’t look too difficult to do it myself. Less than an hour later—fixed! Thanks a ton!
This was an excellent tutorial. I followed it step by step. My only mistake was not seating the new adapter fully, which caused the rod to sit too far from the flame. Realized my error, took everything apart again, and fixed it. Thanks for sharing this! I used the Resideo thermocouple as you suggested and picked it up from the local Lowe’s.
Thanks again—great job!
Thank you so much for saving me a ton of money! A gas company representative came out to check for leaks and troubleshoot why my heater wasn’t working. He kindly pointed out that the thermocouple was faulty. He even disassembled and reassembled it in front of me, explaining that all I needed was a new thermocouple. Unfortunately, I forgot the exact steps. Thanks to your tutorial, I was able to remove the burner, install the new thermocouple correctly, and now I have hot water again.
Really appreciate this informative post!