Ford Rotunda Approved SF99 Servo Bore Repair System: 5RW
1. Install the drill jig into the case by setting the jig into the servo. Retain the jig in the case with the servo’s snap-ring.
2. Drop the 9/16” guide into the jig. It doesn’t matter which one of the lands on the guide you use, as long as one of the lands is under the 3/8” Allen screw.
3. Ream out the bore using the 9/16” reamer, applying ample lubrication.* DO NOT REAM ABOVE 500 RPM.
4. Replace the 9/16” reamer guide with the 5/8” guide, and the 9/16” reamer with the 5/8” reamer.
5. Ream the bore out using the 5/8” reamer with ample lubrication.* Take care not to either push too hard on the reamer or turn the reamer faster than 500 RPM when reaming. Either one can overly enlarge the bore, causing a loose bushing.
6. Clean the case before proceeding to step number seven.
7. Apply Loctite® (preferably green #680) or equivalent to the bushing and drive the bushing in by hitting the driver until the bushing bottoms. The 5RW kit uses a smaller diameter installation tool identified by a groove cut in the handle.
8. After installing the bushing, using a 15/64” bit, drill a hole in the side of the bushing by following the holes in the case (use the appropriate picture to the left as a map).
9. Insert the provided sizing pin into the bore. It may be necessary to start the pin in the bushing with a rubber mallet. Once the pin is inside the bushing, use a punch to drive the pin all the way through the bushing. Repeat as necessary.
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