Lokar Cable Operated Sensor Kit-Ford - Manual

Lokar Cable Operated Sensor Kit
IMPORTANT: Read all mounting options and instructions thor-
oughly before beginning installation. These instructions provide
some typical mounting options. Choose the instruction best
suited for the needs of this installation.
MOUNTING OPTIONS: The cable operated sensor kit consists
of 3 main components. The sensor, decoder box and sensor
mounting brackets.
The Lokar Cable Operated Indictor Kit is equipped to mount
the sensor on the transmission or some remote location under
the body within 5 feet of the transmission selector shaft.
For a remote mounting location inside the vehicle a Lokar
Remote Mounting Cable Kit will be required. Part No:
CINR-1796. This provides 7 more feet of mounting
capability, for a total of 12 feet.
The decoder box should be mounted inside the vehicle out of
the elements. A transmission specific sensor bracket is supplied
and mounts on the transmission. A universal sensor bracket is
also supplied that gives the flexibility of mounting the sensor in
a location of choice other than on the transmission.
WARNING: Disconnect battery before beginning installation.
Make sure vehicle is in Park and that the tires are scotched.
Building American Quality… With A Lifetime Warranty!
Ford AOD , AODE & 4R70W Transmissions
Lokar Cable Operated Sensor Kit
Lokar Cable Operated Sensor Kit Installation
OPTION I: MOUNTING THE SENSOR ON THE TRANSMISSION
WITH A LOKAR SHIFTER
Step 1: When installing the sensor on the transmission the sensor
must be mounted on the passenger side of the transmission.
Using the supplied bolts, washers and spacers attach the
sensor bracket to the transmission using the first and second
pan bolts to the rear of the dipstick hole.
Photo 1
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Page 1 © 2008 Lokar, Inc. Rev. 04/29/08
Step 2: Snug bolts but do not tighten at this time. Mount the sensor to
the trans bracket using the 8-32 x 5/16 long button head screws
and # 8 lock washers to attach the sensor to the bracket. Adjust
the sensor and bracket forward or backwards until the sensor arm
can move through its full travel without the sensor arm interfering
with the trans case. Tighten the mounting bolts. Mount the adjust-
able cable bracket on the driver side of the transmission using
the second pan bolt to the rear of the selector shaft. Adjust the
bracket (flat with the hole) to approximately 90 degrees to the pan
rail. This will be final adjusted later in this installation.
Photo 2
Step 3: Install the AOD indicator arm. The arm needs to mount on top of
the stock Ford selector shaft arm with hook down and the 7/16
bolt going through the hole in the indicator arm. The two tabs on
the Lokar trans lever adapter will keep this centered.
Photo 3
Step 4: Install the cable housing between the sensor housing and
the adjustable cable bracket. Route the cable housing from the
adjustable cable bracket to the sensor. Remove the two flat head
screws in the sensor cap on the sensor housing. Fit the cable
housing between the sensor housing and the sensor cap. There
is a groove in the sensor housing to receive the cable housing.
Mark the cable housing at this point. Remove the cable housing
from the brackets. (NOTE) Tape the cable housing and use a
fine tooth hacksaw blade to cut the cable housing. Before mov-
ing forward be sure the end of the cable housing is open and
the inner wire will slide in without interference. Install the cable
housing into the sensor housing by clamping it between the alu-
minum body and the removable cap. Install the other end back
into the adjustable cable bracket and tighten. (NOTE) It is very
important that the cable housing is secured. Fasten the cable
housing tightly so there is no slack or movement in the housing.
Slide the inner wire into the cable housing until it is protruding
out both ends. Install the brass hex cable stop into the sensor
arm. Put the compression spring on the inner wire between the
sensor arm and the sensor body. Slide the inner wire through
the cable stop and DO NOT tighten the set screw. The inner wire
needs to run in as straight a line as possible between the sensor
and the sensor body. Make sure the inner wire is on the correct
side of the sensor arm.
Photo 4
Step 5: Adjust the angle of the cable mounting bracket so that
the cable does not bind or kink as it goes through its gear
selections. Install the brass cable stop on the other end
of the cable at the trans arm. Slide the inner wire into the
cable stop and tighten the set screw.
Photo 5
Step 6: Adjust the cable. (NOTE) It is very important that the cable
housing is secured. Fasten the cable housing tightly so
there is no slack or movement in the housing. Put the trans-
mission in park. Adjust the sensor arm so that the slot in
the shaft and the set screw on the top of the sensor arm are
in line. Push the arm up against the compression spring,
with about 1/8" of tension against the spring. Tighten up
the set screw in the brass cable stop. Trim excess inner
wire leaving about 1" inch on both ends. Shift the trans
from park, one gear at a time, check each gear and make
sure that the arm on the sensor
does not hit the stop screws.
The sensor arm does not need to be the same distance from
the stop screws in park as it is in low gear. To get more
clearance loosen up one side of the inner wire at the brass
cable stop and move the arm. After the sensor is operating
properly and no more adjustments need to be made cut the
excess inner wire within 1/2 inch of the brass cable stop.
The sensor can now be programmed.
OPTION II: MOUNTING THE SENSOR ON THE TRANSMISSION WITH
LOKAR AOD, AODE AND 4R70W TRANSMISSION SELECTOR
SHAFT AND ARM
After installing the Lokar AOD, AODE and 4R70W selector shaft
and arm the installation of the cable operated sensor is the same
as Option I. The only difference is there is no adapter to pinch in
between the stock Ford linkage (which is no longer used) and the
Lokar trans arm adapter (which is no longer used).
OPTION III: MOUNTING SENSOR IN A REMOTE LOCATION WITH
LOKAR SHIFTER & LEVER ADAPTER OR WITH LOKAR
AOD, AODE AND 4R70W TRANSMISSION SELECTOR
SHAFT AND ARM USING A REMOTE MOUNTING CABLE
KIT (FORD AOD TRANSMISSION)
™
Ford AOD , AODE & 4R70W Transmissions
(Continued on page 2)