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LINKAGE: CONROD REPAIR AND REPLACEMENT
CONRODS AND LEVERS ARE OFTEN MAINTAINED AND REPAIRED TOGETHER. FOR LEVER INSTRUCTIONS, SEE THE LEVER REPAIR PAGE.
CONROD DISASSEMBLY
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REMOVE THE COTTER PIN, CONROD COLLAR, CONROD AND WASHER FROM EACH CONROD LINKAGE.
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REMOVE THE CONRODS FROM THE LEVER ASSEMBLIES, MARKING EACH CONROD AND ITS LOCATION TO MAKE REASSEMBLY EASIER.
CONROD REPAIR AND REPLACEMENT
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EXAMINE EACH CONROD FOR WEAR OR DEFORMATION OF HOLES.
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CHECK ALL CONROD BUSHINGS FOR WEAR. IF A BUSHING MUST BE REPLACED, REMOVE IT WITH A PUNCH (OR A STEPPED TOOL MADE FROM 1-1/4" ROUND ROD STEPPED DOWN TO A DIAMETER OF 0.92" AND THEN TO 0.73".)
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EXAMINE ALL THE STUDS AND REPLACE ANY THAT ARE LOOSE OR HAVE BADLY WORN BEARING SURFACES. THE PREFERRED METHOD TO REPLACE A STUD IS SWAGING BUT IN A PINCH STUDS CAN BE TEMPORARILY WELDED TO CONRODS.
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IF NECESSARY, CHASE STUD THREADS WITH A 5/8-18-3 UNF CHASER. BRASS COLLARS CAN BE CHASED WITH A 5/8-18-3 UNF TAP. NOTE: USE A 1/8" DIAMETER WELDING ROD STUCK IN A COTTER PIN HOLE TO TURN THE COLLAR; DO NOT USE PLIERS BECAUSE YOU WILL MAR THE SURFACE OF THE COLLAR.
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SCRAPE, SAND AND PAINT ALL STEEL LINKAGE PARTS AS NECESSARY TAKING CARE TO AVOID BEARING SURFACES. IF YOU PAINT THE PARTS, USE FORMULA 150 PRIMER AND FORMULA 151 TOP COAT.
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IF CLOSURE LINKAGES HAVE MORE THAN 1/8" PLAY OR APPEAR WORN, REPLACE THE BUSHINGS. THE REPLACEMENT SHOULD BE DONE BY PRESSING THE PARTS IN A VISE OR BY USING A TOOL MADE FROM 1-1/4" ROUND STEEL ROD STEPPED DOWN TO 0.73".
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WHEN INSTALLING A CONROD, APPLY A LIGHT COAT OF SILICONE COMPOUND TO THE BUSHINGS AND BEARING SURFACES OF ALL STUDS. COAT THE STUD THREADS WITH ANTI-SEIZE COMPOUND.
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PLACE ONE WASHER ON EACH STUD BETWEEN THE CONROD AND LEVER AT EACH LINKAGE CONNECTION.
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ATTACH A BRASS COLLAR TO EACH LINKAGE CONNECTION AND HAND TIGHTEN.
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AT EACH STUD, ALIGN THE HOLE IN THE COLLAR WITH THE HOLE DRILLED IN THE STUD, INSERT A COTTER PIN AND BEND THE LEGS OF THE PIN FLAT TO THE COLLAR.
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