Lokar Cable Operated Sensor Kit-Ford - Manual (Page 2)

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Page 2
Step 1: A universal mounting bracket that the sensor attaches to is
supplied for mounting in a remote location such as inside the
vehicle, under the dash, in a center console, etc. This bracket
can be used to mount to a body panel or to any part of the
vehicle that is desired. This bracket also keeps the moving part
of the sensor protected from something getting into it. Once
the location has been established that the sensor is going to be
mounted to go ahead and mount the universal mounting brack-
et. Attach the sensor to the bracket using the supplied 8-32
x 5/16 long Phillips head screws. Mount the adjustable cable
bracket on the driver side of the transmission using the second
pan bolt to the rear of the selector shaft. Adjust the bracket to
approximately 90 degrees to the pan rail. A final adjustment
will be made later in this installation.
Photo 2
Step 2: 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 If a Lokar universal AOD, AODE or 4R70W transmis-
sion shaft and arm has been installed the installation of the
cable operated sensor is the same as Option I. The only dif-
ference 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) There are two lengths of cable
housing, The short cable in most cases is the inside cable hous-
ing and has the male fitting swaged on the end. It needs to be
determined where the cable housing will exit the vehicle and
from that point a measurement needs to be made to assure
there is enough cable housing to complete the installation.
(NOTE) It is very important that the cable housing is secured.
Fasten the cable housing tightly so there is no slack or move-
ment in the housing. The farther away the sensor is from the
transmission the more slack there will be in the cable. Remove
as much slack as possible. Once this is done a 5/16 hole needs
to be drilled at the exit point. The second piece of cable hous-
ing will screw into the inside cable housing at the determined
exit point and tightened up. Run the outside cable housing
away from any moving or hot parts. Attach the cable housing to
the adjustable cable bracket. The cable housing needs to be fed
from the rear of the transmission. Install the adjustable cable fit-
ting into the adjustable cable bracket and tighten the two nuts.
Make sure the set screw is in a location that can be tightened up
with an Allen wrench. The cable housing needs to be cut to length
to fit into the adjustable fitting. Pull the cable housing next to the
fitting. Mark the cable housing at the place it is to be cut, slide
the ferrule away from the cut line and do not remove it. Leave
enough cable housing to fit into the fitting. Tape the cable hous-
ing and use a fine tooth hacksaw blade to cut the housing. Before
moving forward be sure the end of the cable housing is open and
the inner wire will slide in without interference. Slide the ferrule
back over the cable housing and insert it into the adjustable fit-
ting and tighten the set screw. At this point the outer cable hous-
ing is attached at two ends; the transmission end and the exit of
the body.
Step 3: Install the cable housing to the sensor. Remove the two flat
head screws in the cap on the sensor. Fit the cable between
the sensor and the bracket. Mark the cable at the point to be
cut. Tape the housing and use a fine tooth hacksaw blade to
cut the housing. Before moving 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 aluminum body and the removable
cap. At this point the cable housing is attached at both ends;
the sensor to the body and the body to the trans.
Step 4: 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 selection. 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
™
Lokar Cable Operated Sensor Kit
Ford AOD , AODE & 4R70W Transmissions
Lokar Cable Operated Sensor Kit
Ford AOD , AODE & 4R70W Transmissions
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. The farther away the sen-
sor is from the transmission the more slack there will be in the
cable. Remove all the slack you can. Put the transmission 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.
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.
MOUNTING THE DECODER BOX
The decoder box must be mounted in a dry place. When mounting
this unit keep it within the reach of the wires on the LED display
and the sensor. The decoder box can be mounted with 2 screws or
double-sided tape. Be sure it is still accessible to hook up wiring and
programming. Reconnect the battery before beginning to program
the gears.
(Continued from page 1)