The seat assembly is heavy. Be careful.
10. Take off both end plates of the mounting box on the seat assembly. Each end plate is held on by four tamperproof screws. Also remove the bottom cover on the mounting block.
11. Remove the rod ends and the pivot arm from the pivot block inside the mounting box. The rod ends are attached to the pivot blocks with shoulder screws. Use an Allen-head wrench and a flat wrench to remove the screws and nuts. Take out the rod ends and pivot arm and lay the assembly aside.
12. Remove the potentiometer bracket with the potentiometer gear and small gear from the bottom of the seat assembly.
13. Remove the large half gear on the bottom of the main shaft. You may want to turn the assembly on its side to do this.
14. Using a punch, hammer out the spring pin in the bottom of the main shaft in the magnet arm. Remove the magnet arm.
15. Turn the seat until you can pull the seat mounting box off the seat assembly.
16. You may need to take the welded seat assembly to a machine shop to do the following items:
a. Remove the old bearings. (They have been press fitted).
b.Turn the bearings, if necessary, to press them into the main shaft on the seat.
c. The inner diameter of the bearings should be turned so that:
• The shaft with a diameter of 1.624 inches should rotate freely when a torque of 10 inch pounds is applied.
• The shaft with a diameter of 1.629 inches must not be able to pass through the bearings.
17. Press the bearings in. (It is not necessary to oil the bearings because they are oil-impregnated.) Insert the main shaft through the top bearing, the shaft holder, the bottom bearing, and the magnet arm.
18. Line up the hole in the shaft for the spring pin with the holes in the magnet arm. Make sure the seat is facing the right direction. Install the spring pin.
19. Put the rod ends and pivot arm assembly back into the seat mounting box, with the right rod end on the right side. Tighten the shoulder screws and nuts to hold the rod ends on the pivot blocks. Do not install the end plates or the bottom cover on the mounting box until the seat assembly is back in the simulator, since you must check the alignment with the seat in the simulator.
20. Install the potentiometer bracket tightly on the bottom of the assembly. The potentiometer and the gears must be lined up correctly so the seat will work right. Turn the small gear until its set screw on the potentiometer shaft is directly below the center terminal on the potentiometer.
21. Turn the seat so that when you install the large half gear, the flat edge of the large half gear is opposite the small gear and is parallel to the sides of the assembly. Put the gear on tightly.
22. Lift the assembly into the simulator. Push it forward and back to ease it into position, under the floor. Be careful not to damage the gears and the potentiometer.
23- Install all the screws and nuts that hold the seat assembly in the simulator.
24. Reinstall the coin box and re-connect the harness.
25. Put the shifter back in the simulator. Put the lock-nuts on the tamperproof screws and the carriage bolts. Re-connect the harness.
26. Put the shifter gate back on, with the latch and the spring facing down. Then put the boot with the foam and boot cover plate on. Install the four tamperproof screws in the cover plate. Install the knob.
27. Re-install the floor. Put in the screws in the front of the floor and the screws in the metal floor trim.
28. Turn the mounting box until the seat mounting platform is square with the mounting box and parallel to the sides of the simulator. If it is not, then rotate the pivot arm until it is. When everything is square, tighten the nut on the right rod end against the pivot arm. Check this alignment again to make sure the mounting box is parallel to the front of the simulator and the seat mounting platform is square with the box.
29- Install the end plates of the mounting box with the tamperproof screws. Put the bottom cover back on.
30. Enter the self-test, go to the Set Controls screens, and re-initialize all the controls.
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