Sundance/Jacuzzi Theramax 2.5 HP Legacy Spa Pump

Product Overview

As a retailer of hot tub spare parts, I’m featuring the Sundance/Jacuzzi Theramax pump, a 2.5 HP single-speed replacement pump that carries forward the legacy of Sundance’s trusted pump designs. This 48-frame pump continues the heritage of the specially designed Aqua-Flo XP series pumps.

Key Benefits

• Classic 48-frame construction
• Standard 2″ plumbing connections
• Side discharge configuration
• Consistent 10 amp performance
• Direct replacement compatibility
• Heritage Theramax design
• Proven reliability record

Technical Excellence

The Theramax series represents the evolution of Sundance’s pump technology, building upon the success of both the Vico “Ultra Jet” and Aqua-Flo XP series pumps. This model maintains the reliable performance characteristics that made these pumps popular in classic Sundance spa installations.

Historical Context

• 1994-1996: Vico “Ultra Jet” Pump era
• 1997-1999: Primary Aqua-Flo XP Series usage
• Current: Modern Theramax design evolution

Replaces 6500-126, 6500-131, 6500-263, 6500-266, 6500-269, 6500-763, 6500-766, 6500-767, 6500-769

Can replace 2500-251 though for this one it would need to be re-plumbed with bracket 6000-532.

Technical Specifications

Installation Notes

The pump requires a separate mounting bracket (Part #6000-532, sold separately) for installation. Features standard 2″ connections for straightforward plumbing compatibility. Please note that this model does not include a power cord or foot base.

Performance Features

Single-speed operation provides reliable performance:

• 10.0 Amp motor for consistent operation
• Classic 48-frame design
• Side discharge configuration
• Standard port sizing
• Traditional mounting compatibility

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	Magic Plastics Union 0602-15 (1.5″ Pump Union) | 1-1/2″S x 1-1/2″FBT Union, Pump, Magic, 1-1/2"S x 1-1/2"FBT (Industry Standard) w/ O-Ring	$6.05 Max: 291 Min: 1 Step: 1 Add to cart
	Magic Plastics Union 0602-20 (2″ Pump Union) | 2″S x 2″FBT w/ O-Ring Union, Pump, Magic, 2"S x 2"FBT (Industry Standard) w/ O-Ring	$7.63 Max: 421 Min: 1 Step: 1 Add to cart
	Waterway Union 400-6010 | 2-1/2″ Union Nut with 2-1/2″ Slip tailpiece and o-ring (2.5″ union) Union, Pump, Waterway, 2-1/2"FBT x 2-1/2"S	$14.77 Max: 33 Min: 1 Step: 1 Add to cart
	1 Speed Pump / Blower / AMP Cord | 21086 Amp Plug, Pump, 1-Speed, 14/3, 4-Pin, 5' Cord, White	$20.10 Max: 354 Min: 1 Step: 1 Add to cart
	Balboa Amp Plug 21087 (For 2 Speed Pumps) Amp Plug, Pump 1 (2-Speed) 14/4, 72" Long, White	$31.72 Max: 108 Min: 1 Step: 1 Add to cart

Hot Tub Pump Collar & Union Size Chart

Imperial & Metric Specifications

Union Size	Collar Size	Thread OD	Union OD	O-Ring Size
1.5" Female Buttress Thread (FBT)	2.5" / 64mm (Tip to Tip) Measurement	2-1/2" 64mm	2-13/16" 71mm	2-5/16" OD 59mm
2" Female Buttress Thread (FBT)	3.1" / 78mm (Tip to Tip) Measurement	3-1/16" 78mm	3-3/8" 81mm	2-15/16" OD 75mm
2.5" Female Buttress Thread (FBT)	3.6" / 91mm (Tip to Tip) Measurement	3-5/8" 91mm	4-1/4" 108mm	3-7/16" OD 87mm

Important Notes

The union "size" (1.5", 2", 2.5") is nominal and doesn't correspond to any actual measurement.

Collar size is measured from thread tip to thread tip on the pump outlet.

Most hot tub pumps use Female Buttress Thread (FBT) - 98% of applications.

O-ring gaskets may vary between manufacturers - measure your existing gasket for accuracy.

How do I Replace a Hot Tub Pump?

Here's a general step-by-step guide on how to replace a hot tub pump. Keep in mind that the specific steps may vary depending on your hot tub's make and model, so it's essential to consult your hot tub's manual for model-specific instructions. If you're not comfortable with this procedure, it's a good idea to seek professional assistance.

Materials You'll Need:

• Replacement pump
• Pipe wrench
• Adjustable wrench
• Screwdriver
• Pipe sealant (thread tape or plumber's putty)
• PVC primer and cement (if you have PVC plumbing)
• Teflon tape (for threaded connections)

Procedure:

1. Turn Off the Power: Before you begin, ensure the hot tub's power supply is turned off at the circuit breaker or disconnect switch. Safety should always be a priority when working with electrical components.

2. Drain the Hot Tub: If your hot tub is not already empty, you'll need to drain it. Follow your hot tub's manual or manufacturer's instructions for proper draining. (You might not need to do this if you can lock the pump off with the gate valves)

3. Locate the Pump: Identify the location of the existing pump in your hot tub. It's usually located near the equipment area or in a designated pump compartment.

4. Disconnect the Electrical Wiring: Carefully disconnect the electrical wiring from the old pump. This typically involves removing the electrical conduit cover, unscrewing wire nuts, and disconnecting the wires from the terminals. Be sure to note the wire connections or take a picture for reference when connecting the new pump.

5. Disconnect the Plumbing: Depending on your hot tub's plumbing setup, you'll need to disconnect the plumbing connections to the pump. Use a pipe wrench or adjustable wrench to loosen and remove the fittings. Be prepared for some water spillage when disconnecting the plumbing.

6. Remove the Old Pump: Once the electrical and plumbing connections are detached, carefully remove the old pump from its mounting position. Some pumps may be secured with mounting brackets or bolts.

7. Prepare the New Pump: If the new pump is not pre-assembled, you may need to attach fittings, unions, or adapters to match your hot tub's plumbing. Ensure that you use the appropriate sealant or Teflon tape on threaded connections to prevent leaks.

8. Mount the New Pump: Position the new pump in the same location as the old one and secure it in place using the mounting brackets or bolts.

9. Reconnect Plumbing: Reconnect the plumbing to the new pump, ensuring that all connections are tight and secure. If your hot tub uses PVC plumbing, use PVC primer and cement to bond the connections properly.

10. Reconnect Electrical Wiring: Reconnect the electrical wiring to the new pump, following the notes or pictures you took earlier. Make sure all wires are properly connected and secure.

11. Turn On the Power: Restore power to the hot tub by switching on the circuit breaker or reconnecting the disconnect switch.

12. Test the Pump: Turn on the hot tub's pump to ensure that it's working correctly. Check for any signs of leaks or irregularities in the plumbing connections.

13. Refill the Hot Tub: Once you've confirmed that the new pump is functioning properly, refill the hot tub with water.

14. Check for Leaks: Inspect the plumbing connections for any leaks. If you find any, turn off the pump, drain the tub again, and reseal the connections as needed.

15. Monitor: Keep an eye on the pump and plumbing for the next few days to ensure everything is functioning correctly and that there are no further issues.

Remember that this is a general guideline, and the specific steps may vary based on your hot tub's design. If you're unsure or uncomfortable with any aspect of this process, please do get in touch, happy to help.

How do I know what size hot tub pump I have?

Determining the size of your hot tub pump is an important step when it comes to maintenance or replacement. To find out the size of your hot tub pump, follow these steps:

1. Check the Manual: The easiest way to determine the size of your hot tub pump is to consult the owner's manual or user documentation that came with your hot tub. The manual typically contains detailed information about the specifications and components of your hot tub, including the pump.

2. Look at the Pump Housing: If you don't have access to the manual or it doesn't provide the information you need, inspect the pump itself. Most hot tub pumps have a label or plate on the pump housing that displays essential details, including the pump's model number, manufacturer, and specifications. You can then send that to me or Google it.

3. Measure the Pump: If the label is missing or damaged, you can measure the pump's dimensions. Measure the diameter of the pump's wet end (the part where the water flows) and the length of the wet end. These measurements can help identify the size and capacity of the pump.

4. Consult the Manufacturer: If you can't find the information on the pump or in the manual, contact the hot tub manufacturer or a reputable dealer. Provide them with your hot tub's model and serial number, and they should be able to identify the correct pump size for your specific hot tub.

5. Online Research: You can also search online using the pump's model number or hot tub's make and model. Many manufacturers provide detailed information about their products on their websites, and you may find specifications for your pump model.

Once you have determined the size and specifications of your hot tub pump, you can proceed with maintenance, repairs, or replacement if necessary. Keep in mind that replacing a hot tub pump with the same size and capacity as the original is crucial to ensure proper water circulation and filtration in your hot tub. If you're unsure about any aspect of this process, get in touch, always happy to help.

Alternate Part Numbers

• 4234110-S
• SD6500341
• SD-6500341
• SD6500-341
• SD-6500-341
• 6500341