Servo Bore Repair

NOTE: The 4F27 Servo Bore Master Repair Kit NRL4F27 should be used to repair a transmission case with 2-4 band servo pin bore wear. The use of this kit will repair the 2-4 band servo pin bore back to OEM specifications.

Install the drill jig and the 6mm bolts.

Fig 1: Installing Drill Jig And The Three 6mm Bolts
Courtesy of FORD MOTOR CO.
Secure the 7/16" guide into the jig using the 3/8" allen screw.

Fig 2: Securing 7/16" Guide Into Jig Using 3/8" Allen Screw
Courtesy of FORD MOTOR CO.

NOTE: Cutting oil must be used for lubrication. The use of substitutes, particularly ATF, may result in an over-sized bore.

NOTE: When reaming the servo bore do not push too hard on the reamer or exceed 500 RPM or an over-sized bore can occur.

Fig 3: Reaming Out Bore Using Ample Cutting Oil And Properly Sized Reamer

Courtesy of FORD MOTOR CO.

Ream out the bore using ample cutting oil and the 7/16" reamer.
Secure the 1/2" guide into the jig using the 3/8" allen screw.

Fig 4: Securing 1/2" Guide Into Jig Using 3/8" Allen Screw
Courtesy of FORD MOTOR CO.

NOTE: Cutting oil must be used for lubrication. The use of substitutes, particularly ATF, may result in an over-sized bore.

NOTE: When reaming the servo bore do not push too hard on the reamer or exceed 500 RPM or an over-sized bore can occur.

Fig 5: Reaming Out Bore Using Ample Cutting Oil And Properly Sized Reamer

Courtesy of FORD MOTOR CO.

Ream out the bore using ample cutting oil and the 1/2" reamer.
Thoroughly clean the transaxle case to remove any metal debris.

Fig 6: Thoroughly Clean Transaxle Case
Courtesy of FORD MOTOR CO.
Apply Loctite® 680 or equivalent to the outside bushing.

Fig 7: Appling Loctite® Or Equivalent To Outside Bushing
Courtesy of FORD MOTOR CO.

NOTE: Make sure the 1/2" reamer fits smoothly through the hole before installing the bushing.

Fig 8: Aligning Hole In Side Of Bushing With The V Shaped Notch

Courtesy of FORD MOTOR CO.

Align the hole drilled in the side of the bushing with the v shaped notch cast into the case.
Using the driver, drive the bushing in until the bushing chamfer is flush with the transaxle case.

Fig 9: Driving Bushing Into Transaxle Case
Courtesy of FORD MOTOR CO.

NOTE: Check the pin finish for burs and coarseness.

Fig 10: Checking Pin Finish For Burs And Coarseness

Courtesy of FORD MOTOR CO.

Insert the sizing pin into the bore, chamfer side first. Using a punch, drive the pin all the way through the bushing. Repeat as necessary.