BUSHING REPLACEMENT:  SELF-LUBRICATING BUSHINGS

SELF-LUBRICATING BUSHINGS FOR USE IN DOG ASSEMBLIES DON'T USE STRING OR STICK PACKING AND PROVIDE SERVICE ADVANTAGES.  HOWEVER, THE NEW BUSHING ASSEMBLIES HAVE PLASTIC AND SILICONE ELEMENTS THAT MAY REQUIRE EXTRA CARE ON THE PART OF DAMAGE CONTROL AND MAINTENANCE SPECIALISTS DURING INSTALLATION OR REPLACEMENT.

1. REMOVE THE EXISTING DOG ASSEMBLY AND DOG POINT SET SCREW.  IF THE SET SCREW CANNOT BE REMOVED, DRILL ITS LOCATION AND TAP FOR THE 1/4-20 UNC SET SCREW FURNISHED IN EVERY REPAIR KIT.
   
   
2. CLEAN ALL PACKING RESIDUE FROM THE DOG SLEEVE WITH A RAG AND SOLVENT.
   
   
3. FOR STEEL DOORS, REMOVE ANY DIRT OR CORROSION FROM THE INSIDE OF THE SLEEVE WITH #320 GRIT OXIDE CLOTH.  CLEAN AWAY ANY GRIT WITH A RAG AND SOLVENT.
   
   
4. CLEAN THE DOG SPINDLE WITH A RAG AND SOLVENT.
   
   
5. USING A SOFT-FACED HAMMER, INSTALL THE PLASTIC PLUG IN THE TRANSVERSE HOLE IN THE SPINDLE.  LEAVE THE PACKING PLUNGER IN PLACE.  (TAKE EXTRA CARE NOT TO DAMAGE THE SPINDLE.)
   
   
6. DAUB A THIN COATING OF SILICONE COMPOUND ON THE INTERIOR OF THE NEW FLANGED BUSHING.
   
   
7. TRIAL FIT THE NEW BUSHING TO THE SPINDLE TAKING CARE NOT TO DAMAGE THE TEFLON RING.
   
   
8. DAUB A THIN COATING OF SILICONE COMPOUND TO THE EXTERIOR OF THE FLANGED BUSHING.
   
   
9. TRIAL FIT THE BUSHING INTO THE DOG SLEEVE.
   
   
10. DAUB A THIN COATING OF SILICONE COMPOUND TO THE INNER SURFACE OF THE DOG SLEEVE ON THE EXTERIOR (PANEL) SIDE OF THE DOOR.
    
    
11. TRIAL FIT THE STRAIGHT BUSHING INTO THE SLEEVE.
    
    
12. USE THE BLACK MARK ON THE EDGE OF THE FLANGE BUSHING TO GUIDE ALIGNMENT OF THE HOLE IN THE BUSHING WITH THE HOLE IN THE SLEEVE.  YOU SHOULD MARK THE POSITION OF THE SLEEVE HOLE ON THE OUTSIDE CIRCUMFERENCE OF THE SLEEVE.
    
    
13. APPLY A THIN COATING OF ADHESIVE/SEALANT TO THE OUTER EDGE OF THE DOG SLEEVE.  IMMEDIATELY WORK THE O RING INTO THE DOG SLEEVE AND PRESS THE FLANGED BUSHING TO A SNUG FIT.
    
    
14. INSTALL THE CRES DOG POINT SET SCREW AND ROTATE THE SET KEY ONE TURN.  DO NOT TIGHTEN THE SET SCREW.
    
    
15. APPLY A THIN COATING OF SILICONE COMPOUND TO THE LEVER OR DOG SPINDLE AND TO THE EXTERIOR OF THE STRAIGHT BUSHING.
    
    
16. CAREFULLY INSERT THE SPINDLE INTO THE SLEEVE.
    
    
17. REMOVE THE TAPE THAT HOLDS THE THRUST WASHER AND FLANGE BUSHING TOGETHER.
    
    
18. INSTALL THE REMAINDER OF THE DOG ASSEMBLY (EXCEPT FOR THE SECOND JAM NUT IN ASSEMBLIES THAT USE PAIRED JAM NUTS).
    
    
19. APPLY ANTI-SEIZE COMPOUND TO THE SET SCREW AND TIGHTEN IT TO NEAR FLUSH WITH THE SURFACE OF THE DOG SLEEVE OR UNTIL YOU FEEL FULL TIGHTNESS.  THEN BACK OFF THE SET KEY 1/2 TURN.
    
    
20. REPEAT STEPS 1 THROUGH 19 FOR EACH DOG ASSEMBLY.
    
    
21. ADJUST THE DOGS.
    
    
22. PERFORM A CHALK TEST.
    
    
23. FOR DOG ASSEMBLIES USING JAM NUTS, INSTALL THE SECOND JAM NUT ON EACH ASSEMBLY.