LINKAGE:  LEVER REPAIR AND REPLACEMENT

LEVERS AND CONRODS ARE OFTEN MAINTAINED AND REPAIRED TOGETHER.  FOR CONROD INSTRUCTIONS, SEE THE CONROD REPAIR PAGE.

1. FOR EACH DOG AND LEVER ASSEMBLY, REMOVE THE SELF-LOCKING NUT OR TWO JAM NUTS AND THE ROTATING DOG.
   
   
2. REMOVE THE LEVERS FROM THE SPINDLE SLEEVES TAKING CARE TO MARK EACH LEVER AND ITS LOCATION FOR LATER REASSEMBLY.
   
   
3. REMOVE THE STRAIGHT BUSHINGS AND COMPRESSION SPRINGS FROM THE SPINDLE SLEEVES.
   
   
4. USE AN ALLEN WRENCH TO LOOSEN THE SET SCREW ON EACH FLANGED BUSHING AND REMOVE THE FLANGED BUSHINGS FROM THE SPINDLE SLEEVES.
   
   

1. EXAMINE EACH LEVER TO SEE THAT THERE ARE NO DEEP SCRATCHES OR GROOVES IN THE BEARING SURFACES.  REPLACE BEARINGS THAT ARE DEEPLY SCORED.
   
   
2. EXAMINE ALL STUDS TO MAKE SURE NONE ARE LOOSE.  ALSO CHECK BEARING SURFACES FOR WEAR.
   
   
3. CHASE ANY WORN THREADS ON LEVER SPINDLES WITH A 7/8-9-2 UNC DIE.
   
   
4. REMOVE THE PACKING PLUNGER FROM THE OUTER HANDLE SPINDLE.  INSPECT THE PLUNGER AND IF ITS SCREWDRIVER SLOT OR THREADS ARE DAMAGED, REPLACE IT.  HOWEVER, IF THE NEW BUSHINGS WILL BE SELF-LUBRICATING, IT IS NOT NECESSARY TO REPLACE THE PACKING PLUNGER.
   
   
5. 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.
   
   
6. INSTALL NEW BUSHINGS IN THE SLEEVES.  SEE OUR SELF-LUBRICATING BUSHING REPLACEMENT PAGE FOR DETAILS.
   
   
7. DAUB A THIN COATING OF SILICONE COMPOUND ON THE INSIDE OF THE FLANGED BUSHINGS.
   
   
8. COAT THE BEARING SURFACES OF THE SPINDLE WITH SILICONE COMPOUND AND INSERT THE LEVERS INTO THE SPINDLE SLEEVES.
   
   
9. INSERT A SPRING INTO EACH LEVER SPINDLE FROM THE FRONT SIDE OF THE DOOR.  IF THE BEARINGS ARE THE TRADITIONAL TYPE THAT REQUIRES LUBRICATION, WRAP 6" OF STRING PACKING BETWEEN THE SPRING COILS.
   
   
10. COAT THE STRAIGHT BUSHINGS WITH SILICONE COMPOUND AND INSTALL ONE INTO EACH SPINDLE FROM THE FRONT SIDE OF THE DOOR.  MAKE SURE EACH BUSHING SLIDES FREELY UNDER SPRING TENSION.
    
    
11. COAT THE SPINDLE THREADS WITH ANTI-SEIZE COMPOUND.
    
    
12. INSTALL A DOG ON EACH SPINDLE AND ATTACH ONE JAM NUT OR SELF-LOCKING NUT, TURNING IT ONLY THREE THREADS DEEP.  MAKE SURE THE LEVERS TURN SMOOTHLY.
    
    
13. ADJUST THE DOGS.
    
    
14. PERFORM A CHALK TEST.
    
    
15. FOR HANDLE ASSEMBLIES USING JAM NUTS, INSTALL THE SECOND JAM NUT.