Manifold & Gas Valves Replacement

What's in This Article?

Steps to replace a manifold (gas valves) on a flat top grill.

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Applicable SKUs

FTK0021

How to Replace Traeger Flat Top Grill Manifold with Gas Valves

TOOLS NEEDED:

#2 Phillips Screwdriver
Pliers
3/4” Wrench - open ended or adjustable wrench
5/8” Wrench - open ended or adjustable wrench (cannot be same wrench as ¾”)

1. Remove the Old Manifold with Gas Valves

  1. Unplug the grill from power, close the propane tank and disconnect the regulator.
  2. Use a 3/4" wrench to remove the regulator and hose assembly from the rigid gas manifold.
    regulator_-_rigid_manifold.png
  3. Open the lid, remove cooktop, and set the cooktop aside.
  4. Remove the burner crossover tubes that connect the TrueZone regions.
    1. Remove the four cotter pins.
    2. Lift and slide out the two crossover tubes.
      manifold_-_remove_crossover_tubes.png
  5. Remove the burners.
    1. From the underside of the grill, find and remove the nut, two washers, and wire terminal that connect to the right-side screw of the center burner.
      manifold_-_middle_burner_nut.png
    2. Remove the screws securing the six U-burners to the burner cavity.
      IMPORTANT: The right-side screw on the center burner is longer than the others and will need to be returned to this location at reassembly.
      manifold_-_burner_screws.png
    3. Slide the burners out just far enough that they are no longer inserted into the opening in the burner cavity wall. 
      Theignitor electrodes should not need to be removed from the burner for this.
      manifold_-_remove_burners.png
  6. Remove all three knobs from the gas control valves.
  7. Remove the control panel from the main body of the grill.
    1. Use a Phillips screwdriver to remove the two screws at the bottom of the control panel. Remove and set aside.
      manifold_-_control_panel_screws.png
    2.  Slide the control panel to the right until is stops.
    3. Pull the panel away from the wall of the grill body.
    4. Carefully lower the control panel and let it hang from the wire.
  8. Remove the valve mounting brackets.
    1. On all three valves, remove the three screws attaching the valve mounting brackets to the main body and the screws attaching the knob bushings to the valve mounting brackets.
      Set screws and bushings aside.
      manifold_-_valve_mounting_bracket.png
    2. Remove the three valve mounting brackets by lifting, pulling, and tilting forward.
  9. Remove the old manifold assembly. Note that the valves should remain attached to the manifold and the assembly will need to be rotated to get the end out of the grill.

2. Install the New Manifold with Gas Valves

  1. Install the new manifold by inserting the fitting end into the grill and rotating as necessary to bring the manifold into its correct position.
  2. Reattach the valve mounting brackets.
    1. Slide the bracket bottoms onto the main body wall ensuring that the center tab is behind the wall and the outer tabs are in front of the wall.
      manifold_-_mounting_bracket_install.png
    2. Loosely attach the six bushing screws and the three valve mounting bracket screws.
    3. Place the knobs on the valves and fully tighten the three valve mounting bracket screws.
    4. Remove one of the knobs and tighten bushing screws of that valve, just enough so that the bushing will move when pushed but stays in position.
    5. Insert knob again and ensure that the valve actuates smoothly without binding (in and out movement as well as rotation.
    6. Remove that knob again and fully tighten the two bushing screws.
    7. Reinsert the knob and ensure that it still actuates smoothly. Make adjustments, if necessary.
    8. Repeat for remaining two valves.
    9. Remove all knobs.
  3. Reattach the control panel.
    1. Align the three screws on the main grill body with the large openings of the keyhole slots on the back of the control panel.
    2. Push the control panel toward the main body and then slide it to the left to have the small side of the key slot slide under the screw head.
    3. Inspect the interface between the grill main body and the top of the control panels to ensure that they are flush to one another all the way across the top.
    4. If there are gaps remove and re-install the control panel. The right side shelf bracket can sometimes interfere and make it so the right keyhole slot does not slide under its intended screw head. To correct this, you can:
      • Use the palm of your fist to simultaneously bump the control panel toward the grill body and the left.
      • Remove the right-side shelf and then remove the front right shelf bracket.
    5. Use a #2 Phillips screwdriver to reinstall the two screws at the bottom of the control panel.
  4. Reattach all three knobs.
  5. Reinstall the burners.
    1. Slide the three burners back into position.
    2. Use the six screws to attach the burners to the burner cavity bottom. Ensure that the long one is placed back into the right side of the center burner.
    3. Place the following on the bottom side of the long screw on the right side of the center burner (in order): washer, ground wire terminal, washer, nut. Tighten nut to snug with pliers.
  6. Reinstall crossover tubes.
    1. Place the two crossover tubes into position with opening forward.
    2. Insert the four cotter pins.

3. Reattach the Regulator Hose Assembly

  1. Thread the female fitting of the regulator hose assembly onto the male fitting of the manifold, tightening as much as possible by hand.
    • Resistance before completing two full turns indicates the threads are not aligned correctly (cross threaded), the threads are damaged, or there is debris in the threads.
      Inspect the threads on both fittings, and try again.
  2. Use a 5/8” wrench on the manifold fitting and a ¾” wrench on the hose fitting and tighten the connection.
    Be careful to not over-tighten. It should rotate about 1/16 to 1/8 of a turn past hand tight and then a little more force applied so it is snug.
    manifold_-_attach_regulator_hose.png
  3. Check for gas leaks.
    1. Connect a propane tank to the regulator.
    2. Open the valve on the propane tank but leave all the burner control valves in the off position.
    3. Spray this connection with soapy water and check for bubbles that appear.
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