Lokar Cable Operated Sensor Kit-GM - Manual (Page 3)

Step 6: Remove the existing regular nut from your selector shaft. This kit includes one standard
3/8"-16 trans arm nut and one metric 10mm trans arm nut (has nicks on hex). Install the
trans arm nut that has the correct threads onto the selector shaft.
Step 7: Place the 3/8" internal star washer onto the standoff bolt that matches the trans arm nut
you installed on the transmission. Then install the indicator trans arm onto the standoff
bolt, and install this assembly into the trans arm nut.
With the transmission in Park, adjust the indicator trans arm to the 12:00 to 1:00 position
and tighten the standoff bolt. Fig. 10
Step 8: Remove the inner wire from the cable housing. Temporarily install the threaded end of the
cable housing into the adjustable cable mounting bracket and secure it with the adjuster
nut.
The cable is designed to be cut-to-fit. Route the cable housing from the adjustable cable
mounting bracket to the sensor.
There is a groove in the sensor housing that the end of the cable housing fits in to. Mark
the cable housing at the end of the cable housing groove. Remove the cable housing from
the adjustable cable mounting bracket. Fig. 7 and Fig. 8
Step 9: Make sure that the inner wire has been removed from the cable housing. Wrap tape around the
area to be cut and use an abrasive cutoff wheel or fine-toothed hacksaw to cut the cable
housing at your mark. You also may use heavy duty 8" diagonal cutting pliers. Lokar recom-
mends Klein brand Diagonal Cutting Pliers, # D2000-28 available at The Home Depot or
through W. W. Graingers, Part # 4A838.
Before moving forward make sure the end of the cable housing that you just cut is open and
the inner wire will slide in without interference.
Step 10: Remove the sensor from the sensor bracket using a 5/32" Allen wrench. Reattach the
cable housing to the sensor by clamping it between the sensor housing and the sensor
cap, making sure the cable housing does not extend beyond the end of the cable housing
groove in the sensor housing. Secure the sensor cap using the #10-24 x 1/2" flat head
screws you removed earlier. Then install the threaded end of the cable housing back into
the adjustable cable mounting bracket.
Step 11: Slide the inner wire into the cable housing until it is protruding out both ends. Put the
spring on the inner wire between the sensor arm and the sensor cap.
Install the index cable stop into the sensor arm with the cable hole between the sensor
arm and the sensor. Slide the inner wire through the index cable stop, so that at least 1"
is protruding beyond the index cable stop. Make sure the inner wire is on the correct side
of the sensor arm. Fig. 11
Step 12: Reinstall the sensor onto the sensor bracket using the #8-32 x 5/16" button head screws
and lock washers (transmission mounted sensor bracket) or the #8-32 x 5/16" flat head
Phillips screws (universal mounting bracket).
Step 13: At the opposite end of the cable, install the index cable stop into the trans arm. Slide the
inner wire through the hole in the index cable stop so that approximately 1" is protruding.
You should now have excess inner wire at the opposite end of the cable (at the sensor).
Tighten the set screw in the index cable stop on the indicator trans arm using a 1/16"
Allen wrench. Adjust the angle of the adjustable cable mounting bracket so that the inner
wire will not bind or kink as it goes through the gear selections. Fig. 12
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 cable housing.
Step 14: Make sure the transmission is in Park. Push the sensor arm up against the spring, so that
the spring is compressed approximately 1/8" at rest in Park. Fig. 13 Tighten the set screw in
the index cable stop on the sensor arm using a 1/16" Allen wrench. Trim the excess inner
wire, leaving about 1" protruding.
Shift the transmission from Park, one gear at a time, and check each gear to make sure
that the arm on the sensor does not hit the stop screws or anything else. The sensor arm
does not need to be the same distance from the stop screws in Park as it is in low gear. If
the sensor arm bottoms out before the shifter reaches first gear, loosen up one end of the
inner wire at either of the index cable stops and move the indicator trans arm or sensor
arm. Make sure you maintain approximately 1/8" of compression on the spring at the sensor
end of the cable when the transmission is in Park.
Once the sensor is operating properly and no more adjustments need to be made, cut the
excess inner wire within 1/2" of the index cable stop on both ends of the cable.
Page 3
Fig. 7
Fig. 8 Fig. 9
Inner Wire
Cable Housing
Sensor Arm
Sensor
Bracket
Pan
Bolts
Sensor
Slot in
Sensor
Shaft
Set Screw
End of Cable
Housing Groove
Sensor Cap Sensor Housing
Sensor Arm
End of Cable
Housing Groove
#10-24 x 1/2"
Flat Head
Screws