If your ULTIMAX IRSDUT-ZD90SP II soldering iron has stopped heating properly or takes forever to warm up, there’s a good chance the heating element is worn out. Replacing it is a straightforward process that can bring your soldering station back to life — and save you money compared to buying a new one.
In this guide, we’ll walk through unboxing the replacement heating element, disassembling the soldering iron, replacing the old part, and testing the repair.
Step-by-Step Guide
1. Unbox the Replacement Heating Element
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| Check that it matches the specifications of the original one to ensure compatibility. |
- Start by opening the package containing your new heating element.
2. Disassemble the Tip Assembly
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| Remove the nut, tip enclosure, and soldering tip from the front of the soldering iron. |
- Keep these parts in a safe place for reassembly later.
3. Remove the Cover
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| Unscrew the screws securing the soldering iron’s cover. |
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| Once the screws are out, use a small pry tool to gently open the casing without damaging the housing. |
4. Remove the Old Heating Element
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| Carefully pull out the heating element from the tip section. |
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| Cut any wires connected to it, but make note of their positions — this is important for reconnecting the new element correctly. |
5. Replace with the New Heating Element
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Position the new heating element in place of the old one.
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| Connect the black wire and blue wire together to the longer wire of the heating element. |
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| The short wire from the heating element should connect to the switch. |
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| Use heat shrink tubing to insulate all soldered joints for safety. |
6. Apply Heat Shrink Tubing
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| Use a heat gun to shrink the tubing over the solder joints until it fits snugly. |
7. Reassemble the Soldering Iron
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| Place the heating element back into the nipple section. |
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| Reinstall the switch and all internal components in reverse order of disassembly. |
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| Fit the cover back and tighten the screws. |
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| Reattach the soldering tip, tip enclosure, and nut. |
8. Test the Soldering Iron
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| Turn on the soldering iron and let it heat up. |
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| Clean the tip using a damp sponge or brass wool. |
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| Apply solder wire to ensure it melts smoothly. |
Conclusion
And that’s it! Your ULTIMAX IRSDUT-ZD90SP II soldering iron should now be working perfectly again. This simple repair not only saves you money but also keeps your tools in service for years to come.
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🎥 Prefer Video?
We’ve also made a video guide showing the entire unboxing and replacement process.
If you found this guide helpful, consider sharing it with fellow DIY enthusiasts and technicians who might face the same problem.
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