Explorer AWD V6-4.0L VIN K Flex Fuel (2003)
1.
Install the drill jig into the case by setting the jig into the case servo bore. Retain the jig in the case with the servo's snap-ring. (Figure 2)
2. Drop the 9/16" guide into the jig. It doesn't matter which one of the lands on the guide you use, as long as one of the lands is under the 3/8" Allen
screw.
NOTE
CUTTING OIL MUST BE USED FOR LUBRICATION. THE USE OF SUBSTITUTES, PARTICULARLY ATF, MAY RESULT IN AN
OVER-SIZED BORE.
3. Ream out the bore using the 9/16" reamer applying ample lubrication.
NOTE
DO NOT REAM ABOVE 500 RPM. (Figure 3)
4. Replace the 9/16" reamer guide with the 5/8" guide, and the 9/16" reamer with the 5/8" reamer.
5. Ream the bore out using the 5/8" reamer with ample lubrication. Take care not to either push too hard on the reamer or turn the reamer faster than
500 RPM when reaming. Either one can overly enlarge the bore, causing a loose bushing.
6. Clean the case before proceeding to Step 7. This kit utilizes two different bushings.
