Signs of a Failing Water Heater Thermocouple
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1. Pilot Light Goes Out Frequently
The most prominent symptom is a pilot flame that keeps extinguishing. A healthy thermocouple produces a small electric current when exposed to heat. That current keeps the gas valve open. If the thermocouple is stuck in a "cold" state, the valve will close, and the pilot will extinguish. You may find yourself having to relight the flame over and over.
2. Heater Turns Off While Still Hot
Once the pilot is lit, the heater should remain on, warming water for the following 20‑30 minutes. A failing thermocouple will cause the gas valve to shut off prematurely, even though the water is still hot. You'll see the temperature fall suddenly, and the heater will need relighting every time.
3. Strange Smells or No Heat
A malfunctioning thermocouple can trigger the safety shut‑off, ending gas flow. This might produce a slight chemical odor from the gas or, worse, no heat. If you smell gas or find the water heater’s thermostat reading is far below the set temperature, check the thermocouple.
4. Pilot Light Appears Weak or Flickering
When a thermocouple is marginal, the pilot flame may look weak or flicker. This is because the gas valve is intermittently closing and opening. The pilot may seem steady, but the control is actually unstable.
5. Inconsistent Water Temperature
If the water temperature swings erratically, from hot to lukewarm, the thermocouple could be miscalibrated. Even a slight misalignment can cause the gas valve to open at the wrong times.
6. Wear or Corrosion
Check the thermocouple for visible wear signs. If you find corrosion, cracks, or a broken stem, it can’t generate enough voltage. Over time, the metal can degrade, especially in heaters that sit in damp or humid environments.
7. Pilot Light Lags Behind the Thermocouple’s Movement
If you manually turn the pilot flame on and the thermocouple does not respond quickly, it may be stuck. A lagging response often indicates the sensor is not properly detecting heat.
8. Error Codes or Alarm Lights
Modern gas water heaters may display error codes upon thermocouple failure. A flashing LED or a code on the control panel can point to a "pilot light" or "sensor" issue.
9. Unusual Noise from the Heater
If you hear a rattling or clicking sound when the heater starts, it may indicate the gas valve flickers—another sign of a failing thermocouple.
10. Frequent Pilot Re‑lighting by a Professional
If a plumber has to relight the pilot repeatedly over a short period, it’s a clear indicator that the thermocouple isn’t functioning properly.
How to Fix a Bad Thermocouple
Shut off the gas supply and allow the heater to cool
Detach the old thermocouple using a wrench or pliers
Inspect for corrosion or damage; if you see any, replace it
Clean the connection points and pilot flame area
Put in the new thermocouple, aligning its stem with the pilot flame
Turn the gas back on, relight the pilot, and ensure the heater stays on
If you’re uncomfortable working with gas appliances, call a licensed plumber
A timely replacement can prevent wasted gas, restore hot water, and keep your home safe
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