Inspect all metal parts for dings, gouges, abrasions etc. On all parts except the ball (10), use 320 grit paper to smooth
and remove sharp edges. If ball (10) is damaged (scratched, gouged, etc.) it should be replaced.
Check the groove (round bottom) in the inlet for burrs on the corners. If groove is worn such that burrs exist, use 320
grit paper to smooth and remove sharp edges.
Inspect the small spring-loaded continuity ball (32) located in the face of the unit. Push the ball in and be sure that it
pops back into place. If the ball does not pop back freely, electrical continuity is lost and static discharge is possible.
Replace entire coupling if continuity ball does not pop back out.
Inspect screw (6) and handle (9) for damage. If either part is bent, replace it.
Degreasing solvent MIL-PRF-680, Type III, used to clean parts, is potentially dangerous to
personnel and property. Eye protection is required. Avoid repeated and prolonged skin
contact by wearing rubber gloves or nonporous gloves when handling solvents or material
wet with dry cleaning solvent. Wash hands immediately after exposure with soap and water
and use a lanolin based skin cream to prevent skin drying. Do not use near open flame or
excessive heat. Be sure there is good ventilation or the solvent vapors will build up in the air
and become a poisonous mixture which can cause physical injury or even death.
Rubber gloves should be worn when handling fueling system components due to the toxic
effects of some fuel additives.
Make certain all components are clean and free from oil, grease, or dirt. Wash all parts with an approved dry cleaning
solvent and dry thoroughly with a clean, lint-free cloth.
Place seal (26) into housing (13) with the flat surface inserted into the housing. Press into place with fingers.
Insert seal retainer (25). Work into place with fingers to seat seal (26) and clear groove for seal wire (24).
Avoid damage (scratching, gouging, etc.) to housing surfaces and seal retainer during
installation of wire seal. Gouges or burrs may cause valve to malfunction.
Install open end of seal wire (24) into housing (13) at an angle and slide seal wire down into groove.
Install screws (28) and lug (29).
Install screws (30) and lug (31).
Install bumper (27) onto housing (13) such that the tapered edge is facing toward the housing.
Insert valve ball (10) into housing (13) with shaft flats (33) on ball aligned with shaft holes in housing.
Lightly lubricate replacement O-ring (22) with petrolatum and install bushings (20) and (21) and O-ring (22) onto
attaching-cable-side shaft (19).
Place O-ring (23) into groove in inside end of attaching-cable-side shaft (19) and insert attaching-cable-side shaft (19)
into housing (13) and ball (10).