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Assembly
1. If the ball guide (9) was removed, place the flats of
the displacement rod (1) in a vise. Apply anti-seize
lubricant 222955 to the threads and mating faces of
the rod and the ball guide. Screw the ball guide onto
the rod, hand tight. Remove from the vise. See F
2 on page 8.
2. Install the piston u-cup (35) and bearing (36) on the
piston (12) in the correct order and orientation for
your lower. See F
. 2 on page 8.
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3. Apply anti-seize lubricant 222955 to the threads and
mating faces of the ball guide (9) and piston seat
housing (11). Place the flats of the piston seat hous-
ing in a vise. Place the ball (10) on the piston seat.
Screw the assembled rod (1) and ball guide (9) onto
the piston assembly hand tight, then torque to 468
+/- 24 N•m (345 +/- 18 ft-lb).
4. Lubricate the o-ring (24) and seal (6). Install the
o-ring on the intake seat housing (15). Install the
intake seat housing (15), intake ball (14), ball guide
(12), and seal (6) in the intake housing (15). Set the
intake housing all the way into the vise.
NOTICE
To reduce the possibility of costly damage to the
rod (1) and cylinder (7), first place the cylinder on a
soft block of wood. Always use a rubber mallet or
an arbor press to drive the rod (1) into the cylinder
(7). Never use a hammer to drive the rod.
5. Use an arbor press to reinstall the rod (1) into the
cylinder (7), as follows. (The cylinder is symmetrical,
so either end may face up.) Lubricate the piston
seals (P). With the piston end facing down, lower
the rod into the cylinder. Start the piston into the cyl-
inder as much as possible, then drive the rod and
piston the rest of the way into the cylinder with the
arbor press.
6. Place the cylinder (7) on the intake housing (15).
Tap on the top of the displacement rod (1) with a
rubber mallet, to seat the cylinder.
7. Lubricate the seal (6) and install it in the bottom of
the outlet housing (17). Set the outlet housing on
top of the cylinder (7). Apply thread lubricant to the
six long cap screws (18). Install the cap screws
through the outlet housing (17) and thread them
loosely by hand into the intake housing (15). Tighten
the cap screws oppositely and evenly, then torque to
258 +/- 41 N•m (190 +/- 30 ft-lb).
3A0022A
8. Install the bleeder valve plug (23). The plug has two
sets of threads. Be sure to screw the plug fully into
the valve body (31). Torque the plug to 34 +/- 3 N•m
(25 +/- 2 ft-lb).
9. Lubricate the throat u-cup (37) and install over the
displacement rod (1) into the outlet housing (17) as
.
far as possible. Lubricate the threads and bottom
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face of the wetcup (3), and install it in the outlet
housing (17) until the it bottoms out to press the
u-cup into the outlet housing. Do not torque the wet-
cup yet.
10. Unthread the wetcup (3) completely from the outlet
housing (17). Lubricate the bearing (38) and spacer
(48). Install over the displacement rod (1), bearing
first.
If the spacer is not installed with the bearing, the
u-cup will be crushed when the wetcup is tight-
ened. If this occurs, the u-cup cannot be used and
must be replaced.
11. Verify that the spacer (48) has been installed above
the bearing (38) and reinstall wetcup (3). Torque the
wetcup (3) to 142 +/- 14 N•m (105 +/- 10 ft-lb).
NOTE: Steps 12 and 13 apply only to lowers with
enclosed wet cups (3). See F
12. Install new o-ring (42), wet cup wiper (41), and
wiper seal (40) into wet cup cover (46).
13. Carefully slide wetcup cover (46) over displacement
rod. Line up holes in cover and wet cup. Insert
screws (44). Use a hex head screwdriver to tighten
screws.
Use caution when sliding wet cup cover (46) over
displacement rod (1) to avoid damage to seals (41,
40).
NOTE: It is not ordinarily necessary to remove the
outlet fitting (4) and o-ring (5). However, if they were
replaced because of damage, lubricate the o-ring
and place it on the fitting. Screw the fitting into the
outlet housing (17). Torque to 163 +/- 22 N•m (120 +/-
16 ft-lb).
14. Reconnect the lower to the motor as explained in
your separate pump assembly manual.
NOTICE
. 1.
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NOTICE
Repair
7
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