Apologies in advance for the lengthy post. Short version - I sucessfuly replaced the wash pump, and now I'm getting leaks from the bottom of the front door. Not sure what to do next..
Unit was purchased new about 4 years ago and ran with no issues until recently. Problem developed with failure to start wash cycle. I did some troubleshooting using the technician sheet, and found that the controls were energizing the wash motor, but the motor wasn't responding. I replaced motor, and the new one worked with no issues.
However, when I was testing outside of cabinet, I had some massive leaks from the bottom of the door just a few seconds after the unit went from fill to wash. Initially, I figured out that I'd forgotten to plumb & level it, and that seemed to fix the problem. I ran a few cycles like this (outside of cabinet) and everything was fine.
After putting back in the cabinet, it leaked again, so we pulled it back out for more testing. I've verified that the unit is plumb (placed pocket level vertically on front door) and level (placed pocket level horizontal across top of tub) in line with installation manual, and we're still getting leaks.
Since there were no leaks before pump replacement, and in the few cycles i ran after replacing, then i'm concluding that the door seal is fine and that the level switch is probably fine.
We did run a few test cycles yesterday, and it seems like the lower spray arm may not be spinning. At least - we ran it twice with the arm facing left-to-right across the tub. When we ran the cycle and cancelled after it started leaking, we opened the door and saw that the arm ended up in nearly the same position. We did this twice, so it's either a really weird coincidence or the arm isn't spinning. The upper arms are definitely filling and spinning. We removed the arm itself, and there were no obvious obstructions. We ran faucet water in it and everything flowed fine. The port where the arm attaches didn't have any obvious obstructions, but when we looked down it there was a white plastic plate. From the part diagram, it looks like this is the 'diffuser'. Not sure if this is preventing the arm from filling & spraying or what's going on.
I had my hands on the water supply line, and it does seem like it's continuing to fill even after the wash cycle starts. I can't tell from the technician sheet whether this is correct or not.
Any thoughts about what's going on here? I'm about $100 in to this repair so i'd like to be able to fix this thing rather than replacing.
I'm an industrial controls engineer, so i'm comfortable getting to the control panel and using a multimeter to ohm things out. That's how i correctly diagnosed the wash pump.