Drill Bit Part No. Roughing Reamer Pilot with O-Rings S-56361J-TL Reamer Jig Installation Handle • Drill Bit Finishing Reamer (servo bore) • Roughing Reamer • Finishing Reamer • Guide Pin 1. Preparation & Set-Up • Reamer Jig a. Remove servo assembly from case and thoroughly clean servo pin bore. • Installation Handle b. Test fit Sonnax guide pin in the pin bore to be reamed. If guide pin installs easily, • Pilot proceed to next step. If guide pin sticks in bore, deburr the bore with Sonnax flex • O-Rings (2) hone (included in tool kit S-56361J-TL) until guide pin can be smoothly inserted. • Flex Hone, not shown c. Install Sonnax SERVO-FIX onto case. For SERVO-FIX set-up instructions, please visit www.sonnax.com or refer to instructions included in SERVO-FIX kit.
2. Reaming a. Install reamer jig from tool kit S-56361J-TL into SERVO-FIX. b. Use guide pin from tool kit to align reamer jig properly with bore. NOTE: Once servo pin bore is aligned with the SERVO-FIX, do not disturb or loosen the fixture or guide setting in any way until both reamers have been used and the reaming process is complete. Be sure to use plenty of continuously-supplied cutting fluid during reaming.
c. Gently insert roughing reamer through jig until cutting tip contacts bore opening. d. Use a speed handle or a low-speed, high-torque drill fitted with a wobble adapter to turn the reamer in the bore. Never use a ratchet or pliers. Reaming action must be clockwise in a smooth and continuous motion, at 60-120 rpm. CAUTION: Never turn reamer counterclockwise, not even when removing from bore. Turning counterclockwise will dull or damage reamer. CAUTION
Figure 1 2. Reaming (continued) Case f. Gently insert finishing reamer (reamer marked "Servo Bore") through jig and repeat steps "c" through "e". Pin Bore g. Remove SERVO-FIX. Clean reamers and servo bore with low air pressure and solvent. Feed Hole 3. Tech Tips Use Sonnax To help ease sleeve installation: flex hone to deburr edges a. Thoroughly deburr feed hole in reamed pin bore with of feed hole. Sonnax flex hone (Figure 1). Figure 2 b. Use fine emery cloth to lightly buff outer diameter of sleeve at stepped location (Figure 2).
4. Installation & Assembly
NOTE: Select the correct Sonnax sleeve for the bore being serviced. The Overdrive bore sleeve is the longer of the two (Main image). Although the sleeves are designed as press-fit, use of Lightly buff sleeve retainer (such as Loctite 640) is highly recommended to aid in proper sleeve retention. outside diameter in this area with a. Remove the pilot from Sonnax installation tool by pulling gently. fine emery cloth. b. Slide Sonnax sleeve over small end of installation tool handle, flanged end first (Figure 3). c. Lubricate O-rings on Sonnax pilot. Figure 3 d. Gently push the pilot back into the end of the installation tool, securing sleeve on the tool. (Figure 4). e. Carefully apply a thin coat of sleeve retainer to the upper half outside diameter of Sonnax sleeve. f. Press sleeve into bore by sliding the installation tool pilot into the case bore and then gently pushing/tapping the handle of the installation tool. Press just far enough to seat the sleeve flange against the case bore boss/face (Figures 5 & 6). g. From the inside of the case, gently pull the pilot off the installation tool and set aside. Figure 4 h. Using 15/64" drill bit from Sonnax tool kit, drill the apply hole into the wall of the sleeve, using the existing case apply hole as a guide (Figures 7 & 8).
CAUTION: Ensure drill bit does not contact the opposite wall of the sleeve. CAUTION
i. Remove burrs from the inner diameter of the installed sleeve by inserting the installation tool WITHOUT the pilot attached. j. Reassemble servo per OE specifications.
