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Figured I'd stop back and report the issue is fixed. As suspected, the issue was a combination of the cam and the no.1 valve disc lever. There's no obvious damage to the old one, maybe it was just defective all along, but the new valve disc had a toggle lever that was more than 1/16" longer...

Hah... I was too impatient, and already ordered a new cam, valve discs, and spring assembly last night. I didn't even know I could buy a complete assembly. However, mine is the 255/760, which is mechanically a lot simpler than that old version. In fact, it looks like mine is an "2011 and...

Things got even busier than expected at home and work, and so time to deal with this has been basically zero. That's not due to change in the next several weeks, but after another failed regen I did manage to figure out exactly what's happening. During brine draw, valve discs 1, 4 and 5 should...

Thanks, guys. Sometimes the truth hurts! I'll price out a new unit. As noted previously, cam could be worn, and there could be multiple other age-related deficiencies contributing to this intermittent problem.

Thanks for posting that, Reach4. But I just dug out my prior water analysis, which was taken from a faucet that comes straight of the well (no filter, no softener), and it's showing total iron is only .006 mg/L. Our TDS is a little high 286 mg/L, so I'm guessing whatever red stains we find in...

Yes, we are on a well. Yes, we have iron. What's the process for using Iron Out? Why not just replace the resin? I know the Autotrol isn't the latest and greatest, and will probably replace it with a Fleck at some point. In fact, I replaced an Autotrol with a Fleck in my last house in the...

I'm wondering if those beads could be softener tank media, but then I have to wonder what sort of system setup error has lead to media being pulled out of the tank into the venturi.

We inherited an Autotrol 255/760 on a WG 1040 resin tank with the purchase of this home in 2011, and it was exhibiting brine tank overflows with each cycle at the time we moved it. I replumbed the whole house at the time, but kept this system, as I found it worked fine after re-plumbing the...