Samsung WF42H5600AW: New Bearings & Shocks but Washer Still Makes Racket During Spin Cycle

[lothian.mcadam]

Samsung WF42H5600AW/A2
mfd: April 2014

Issue: Despite new bearings and shocks, washer continues to make a loud noise during spin cycle.

For months, our washer makes an awful racket during the spin cycle and had a small leak. I disassembled the washer and discovered that half of the lower counterweight had broken off. I presume this threw off the tub balance and likely caused premature failure to the shocks and bearings. I found that the broken edge of the lower counterweight had also worn a small hole into the door boot seal—the source of the leak. I replaced the following:

- bearing set (6601-002637 & 6601-000148)
- tub seal (DC62-00156A)
- four shock absorbers (DC66-00470A & DC66-00470B)
- door boot seal (DC97-18094C)
- counterweight (DC67-00749A)

I pressed each new bearing and the tub seal into their respective seat rather than beat them into place. Counterweight, shocks and door boot seal were straightforward part swaps. There were no other issues.

After I put the washer back together, I ran a full test cycle with an empty tub—I heard no unusual noise during wash or spin cycles and I saw no leaks. I then ran the washer with a full load. While there was no unusual noise during the wash cycle, the spin cycle made the same awful racket just as bad as before. The leak, however, is gone.

With the washer spinning, I removed the top and rear covers to try and locate the source of the noise with a flashlight. It seems to be coming from the front right, though I cannot positively identify its source. I jostled the tub from the rear while it was still spinning which had absolutely no affect on the noise, suggesting the tub is NOT making contact with any part of the machine and the new shocks are likely ok. The tub does vibrate (wobble) noticeably with a full load but not so bad that It contacts a body panel of the machine.

I've been spending this evening researching this problem. It's likely the bearings and shocks were never the source of the noise (bearings tend to make a roaring a/o grinding noise when bad) or the shocks (which tend to make a knocking noise when bad and allow excessive movement of the tub during the wash cycle). The new bearings are quiet, of course; and the tub movement during the wash and spin cycles is minimal indicating the new shocks are doing their job. So, bleh.

Loose hoses are definitely NOT not the cause of this racket. It seems a knocking noise during the spin cycle can be caused by three items:
- worn shocks;
- loose counterweights;
- broken drum shaft assembly (aka, "spider").

Here's the thing...
My washer makes noise ONLY during spin cycle, and it can be broken into two distinct sounds: (1) a knocking during initial spin up followed by (2) a loud vibration-type racket during max RPM. Furthermore, knocking occurs at the start of the spin cycle during low RPM as the washer seeks to balance the load; the washer then stops, begins again, stops, restarts, et cetera, some random number of times until it begins to spin in earnest and the loud vibration-type racket occurs. All of this—apparently—are symptoms of a broken spider. ...grumble.

I did inspect the spider when I had the drum out of the tub halves and I did NOT notice any obvious broken bits or anything unusual whatsoever. I did NOT grip the axel shaft to feel for movement, and I regret not having done this simple test.

I need to make a recording of the noise(s) my washer is making.

[lothian.mcadam]

Follow-up.

The bearings were definitely worn. But the actual source of the “violent rhythmic vibration-type racket during the spin cycle” was due to a hairline fracture in one of the arms of the spider (DC97-17004E).

It seems the centrifugal weight of wet clothes caused flexion to the weakened arm that made the drum spin off-center just enough to cause imbalance. Classic negative-feedback-loop scenario. Frankly, we're surprised the thing held together for as long as it did in this condition. A nod of respect to OEM Samsung parts and acknowledgement of build quality is warranted here, methinks. Additionally, I'm certain Samsung's computerized "VRT" (Vibration Reduction Technology) algorithm played an important role in steadying the ship best it could over years of deteriorating circumstances.

Lots of anecdotal information exists that these parts suffer corrosion due from fluid leaking past the tub seal over years of use. This corrosion may lead to premature failure. As a prophylactic measure, we masked off the axel of the spider and coated the entire thing in acid-etching primer with a final top coat of exterior enamel paint. We did this purely to satisfy our own sense of prudence.

We replaced all the parts listed above across four vendors--no one vender offered the lowest price for all necessary parts. Total expense was still less than a service call. One inconvenient week later and the washer works perfectly... and quietly.

Lesson learned: Do NOT let a noisy FLW run undiagnosed for years.