Kohler 84996 Flush Valve

The internals of these toilets are not precision manufactured and slight imperfections in the ceramic can make it such that your new value won't fit without a little "adjusting".Follow these steps for a fairly straightforward install:Tools needed: a small file, utility knife, small hammer with a wooden handle (the kind where it's a little wider in one direction than the other)Step 0:Turn off the water supply to your toilet and flush it.Step 1:Remove the black seal from the new valve body. Attempt to dry fit the new value body by lining up the tangs when inserting it into the toilet's tank. Twist it back to vertical to fully lock the tangs into the toilet's tank. If you encounter tightness or issues getting it into place lightly file or sand around the edges of the round opening on the new valve body. You may also need to file or cut small amounts away from the valve body tangs to get it to fit your toilet perfectly. Observe the tangs on your old valve body to see if there are indicators of where adjustment may be needed on the new one.Step 2:Install the black seal onto the new valve body, remove the red flusher ball and the black axle that connects it to the back of the valve body.Step 3:Place the valve body into the toilet's tank, lining up the tangs so that you are ready to start installation. Insert the wooden handle of the hammer between the valve body and the back of the toilet tank. By twisting the hammer, it should apply enough force to the valve body to compress the black seal and drive the valve body deep into its hole. Finally, use your other hand to turn the valve body back to standing vertically, locking its tangs into place inside the toilet.Step 4:Connect one side of the red flusher ball back onto the plastic axle, then slide the axle back into the appropriate slot on the back of the valve body. With the axle fully inserted you can now connect the other side of the red flusher ball to the black axle.Step 5:Connect the chain to your flusher lever.Step 6:Insider the fill line back into the top rectangular opening of the valve body. Turn on the water. Let your toilet fill, and then do some test flushes.

I tried many of the suggestions here to install this frakin' flush valve. I soaked the gasket in soapy warm water,and I wedged different things between the valve and the back of the tank. Nothing I tried applied enough brute force to compress that gasket enough so that I could rotate the valve to install it.The problem is that the thickness of the gasket is too great to allow all three tabs on the flush valve to be inserted into all three hole notches in the tank, while simultaneously rotating the valve until it is vertical.I'm not a plumber, I'm just a homeowner and no doubt people here will tell me this is not the right way to do it. I don't know if this a permanent solution, or if it will eventually start to leak again. Here is what I did:Using both hands, I twisted the entire gasket 90 degrees so that what had been the thicker part of the gasket now became the surface that will come in contact with the valve and tank wall. The gasket is now less thick than it had been. I was then able to easily install insert the three tabs and rotate and install the flush valve..So far, it's a good seal. The tank is not leaking into the bowl at all. I don't know if that will still be true 6 months or a year from now, but for the meantime, it worked.As far as a review of what Kohler shipped in the box is concerned, it's fine. It includes the plastic flush valve assembly, a new flapper and a new gasket. The only problem was that the gasket is too thick.

It was the correct part—I struggled just like everyone else. Here’s what worked for me:Let the rubber gasket sit in hot water for 2–5 minutes. While it's soaking, practice inserting the valve without the rubber gasket and twisting it into place. You should be able to do this easily before attempting it with the gasket on. It’s important to apply pressure with the valve flat—not at an angle. The valve won't seat properly if it's even slightly tilted. Even without the gasket, it’s nearly impossible to insert if you're pushing at the wrong angle.Once you're comfortable inserting and locking the valve without the gasket, it's time for the real challenge.Enlist the strongest person in your house—you probably won’t be able to do this alone. Position the valve with the gasket in the correct starting orientation and press down with all your might. With the right angle and enough pressure, you should be able to twist it into place.In my case, the top two tabs went in first, but the bottom one gave me trouble. I managed to insert the top tabs, then squeezed hard at the bottom until it clicked in.Hope this helps—and good luck. If you’re reading this, you already know how cursed and annoying this toilet is...