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tomhoo
 
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Default Diagnost/Repair Hexacon Therm-O-Trac 1002

Final update:

Got new element, installed.

Dead.

Discovered broken lead in cord where it flexes at iron.

Cut off end of cord and reinstall. (If anyone has done this, it is
extremely difficult due to crimp brass fitting. Required lathe work,
brass welding, silver soldering, ugh.)

Fired it up and it didn't cycle.

Discovered broken lead in cord where it flexes going into control unit.

Cut of end of cord and reinstall. (This was easy.)

Everything works!

Reassemble iron and spot welded ground wire from new element breaks off
due to excessive weld bead at backside of spot weld. Soldered a lead
to the ground wire, routed outside the iron and looped it around one of
the three screws that hold the element to the handle.

This was a totally insane repair.

What is unfortunate, is that I wasn't familiar with this unit and
essentially ruined the element because the sensor wire was broken.