SF99 Servo Bore Repair System: Ford CD4E
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. Apply Loctite® (preferably green #680) or equivalent to the bushings and drive the bushings in by hitting the driver until the bushing bottoms. The CD4E kit uses the larger diameter installation tool without an id groove cut in the handle.
8. Insert the provided sizing pin into the bore, chamfer first. 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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