Hakko FX-888D Heating Element Replacement TipsThis process has some dangers. Do not attempt it, unless you have the proper skills and tools. I accept no liability for any loss, or harm.Yes, I know that it takes a soldering iron to do this repair. And, it contains tips for repairing a tip. What else you got?
I found the whole process of replacing the heating element to be a little fiddly. But, I am not so young anymore. Here is the procedure that I used to make things go more smoothly; the tips are intended to supplement the instructions that come with the replacement element, not replace those instructions. So, read them before beginning and keep the pamphlet at hand.
1) Cut the old element’s wires, before desoldering them, to keep them from being a heat sink and to give better access for the soldering iron tip. Remove the heating element, save the white insulation tube for some future project and properly dispose of the old element.
2) Secure the extra tiny wires out of the way to prevent melting them. I used a toothless alligator clip.
3) Desolder the remaining wire bits.
4) On the new heating element, slide the red and blue wire covers forward until they cover their lead wires completely. Super-Glue these in place.
5) Slide the white insulation tube forward until its PCB board end is 64mm from the tip end of the heating element. See the instructions. The cover may not be over the heating element, so Super-Glue it to the red and blue covers.
6) Slide the heating element assembly into the spring, before soldering. Divide the red wires from the blue wires with the PCB board. Be mindful to put their colors on the proper side of the board.
7) Insert the red wires into their pad holes. Adjust their length so that the white insulation tube abuts the PCB. Double check that the tip end of the heating element will be 64mm from the end of the PCB.
8 Solder the red wires, now, before you insert the blue wires into their pad holes, because the blue wires will be on top of the red wires’ soldering pads. Clinch the wires down hard against the PCB, to prevent them from piercing the blue wires. Clean the top of the PCB, now, because the blue wires will prevent access for this operation, too.
9) Insert the blue wires into their pad holes and solder. Clean this side of the PCB.
10) Test the assembly for dead shorts, with a multimeter. Also test all resistances, per the instructions.
I hope this helps and that you are successful. Happy soldering!