Remy 42MT Lever Housing - Manual (Page 2)

NOTICE - Only licensed Remy International, Inc. product and component parts should be used, and the use of other parts or modifications not approved
by Remy International, Inc. will void all applicable warranties. The failure to carefully follow these Installation Instructions, set forth above, will void all
applicable warranties. DELCO REMY is a registered trademark of General Motors Corporation, licensed to Remy International, Inc. Pendleton, IN 46064.
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2012 Remy International, Inc. All rights reserved 2
Technical support: USA 800 854 0076, Mexico 01 800 000 7378, Brazil 0800 703 3526, South America 55 11 2106 6510 or visit
delcoremy.com
6. Push the lever pin into the housing until it is fully seated and install the retainer ring.
7. Remove the seal-oil by carefully prying up and twisting on seal with a large screwdriver or pry bar, making sure not to scratch the
inside diameter of the lever housing hole. This is the sealing surface for the outside diameter of the seal.
8. Install the new seal-oil, using a socket or similar device a little larger than outside diameter of the seal and press into place with an
arbor press. Ensure the seal shell is pressed down evenly, not skewed, and flush with the casting.
9. Install the two (2) remaining o’ring.
10. Install the lever housing and drive assemblies, noting alignment marks. Insert shift lever yoke into the drive assembly coll ar during
installation. Install the five (5) mounting screws and torque to 16.3-22.0 Nm (12-16 lb ft). For 37MT motors, install a new
retaining ring into the armature shaft groove and replace the pinion stop.
11. Apply a small amount of SAE20 oil onto the drive housing bushing and install the drive housing assembly, aligning the marks.
Install and torque the six (6) mounting bolts to 17.63-29.8 Nm (13-22 lb ft).
12. If installing the conventional solenoid, reinstall the conventional solenoid plunger assembly and assemble the adjustment nut.
13. Reinstall either the conventional or SSL solenoid. Install and torque the three (3) mounting screws to 14.1-21.4 Nm (10-16 lb ft).
Install the adjustment nut for the SSL solenoid finger tight.
14. Replace ground lead to solenoid ground terminal and torque nut to 1.8-4.3 Nm (16-38 lb in).
15.
DANGER!!! Do not reconnect solenoid motor connector strap to field terminal before adjusting the pinion clearance.
After repair and reassembly, it is necessary before installation on the engine to check and adjust pinion clearance. (See below
graphics)
16. Reinstall access plug and gasket in front of the lever housing and torque plug to a minimum of 8.1 Nm (72 lb in).
17. Reinstall solenoid-to-motor field connector strap.
18. Reinstall field terminal and solenoid motor terminal screws finger tight.
19. Torque field terminal and solenoid motor terminal screws to 8.5-10.7 Nm (75-95 lb in).
20. For insulated models, remove top nut and washer assembly from the solenoid ground terminal and install flexible ground cable.
21. Install ground terminal nut and washer assembly and tighten to 1.8-4.3 Nm (16-38 lb in).
22. Reinstall starter and connect cables and other leads, as removed.
23. Reconnect the negative (-) cable at the battery.
Following these steps carefully is important for adjusting pinion clearance.
Proper care must be exercised when completing these steps to avoid personal injury and/or property damage. Also, to
avoid overheating and possible damage to the solenoid, power should not be applied in excess of one minute.
 DANGER!!! Ensure the stamped metal connector strap is disconnected from the field terminal to prevent the
possibility of motor from rotating.
 Energize solenoid to prevent plunger from rotating and damaging the rubber boot while tightening plunger nut to adjust pinion
clearance.
 Apply appropriate power (12V or 24V) to solenoid between the switch "S" (+) and ground “G” (-) terminals.
 Seat the plunger by simultaneously pushing on 1/2" plunger nut. Note: 24 volts can be obtained by connecting two 12V
batteries in series.
 Adjust plunger nut to obtain the pinion clearance defined based on the motor series being worked on. (See below graphics)
 Remove power immediately after adjustment is completed.