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Repair
3A2012J 47
Repair Catalyst Pump
See F
IG
. 37 on page 49 for reference numbers.
Remove Catalyst Pump from System
1. Flush the pump, see page 30.
2. Relieve the pressure, see page 24.
3. Close catalyst supply ball valve and disconnect fluid
lines.
4. Remove top pivot knob securing catalyst pump to
upper control arm.
5. Remove bolt securing catalyst pump to lower con-
trol arm then remove catalyst pump.
Disassemble Catalyst Pump
6. Pull pivot knob (929) out to fully extend the slave
pump rod (910).
7. Remove quick release pin (908) from slave pump
housing (901).
8. Holding the slave pump housing (901) stationary
with one hand, use a crescent wrench on the flats of
the slave pump cylinder (918) to loosen then
remove the cylinder and foot valve (922) assembly.
9. Place the slave pump housing (901) in a vise. Use
the flats provided by the quick-release pin (908)
hole.
10. Use a crescent wrench on the flats of the
cartridge (902) to loosen then remove the cartridge
and piston rod (910) assembly.
Repair Throat and Piston Seals
11. Use a wrench on the flats of the piston rod (910) to
hold it stationary while using a second wrench on
the flats of the transfer housing (914) to loosen then
remove the housing and cap (917) assembly.
12. Install bullet tool 16D007 on the piston rod (910)
then pull the rod (910) out of the cartridge (902).
13. Remove snap-on seal retainer (902e) then remove
seal (902f).
14. Use crescent wrench to loosen then remove the
bearing (902b) and felt wiper (902d) assembly.
15. Remove seal (902f) from inside of cartridge (902a).
16. Remove o-ring (902g).
17. Install new seal (902f) into bottom of the
cartridge (902a) with the u-cup opening facing into
the pump.
18. Install seal (902f) with onto weep seal installation
tool 16N967 with u-cup opening facing into the
pump then use tool to install seal into inside of
cartridge (902a).
19. Install felt wiper (902d) and bearing (902b) into
cartridge (902a). Tighten to 20-60 in-lb
(2.3-6.8 N•m).
20. Install o-ring (902g).
21. Install snap-on seal (902e).
22. Lubricate the piston rod.
23. With bullet tool 16D007 installed on the piston rod,
install cartridge assembly (902) onto the rod.
24. Remove the bullet tool.
25. Use one wrench on the transfer housing (914) and
another on the transfer housing cap (917) to break
them loose from each other then remove the cap
from the housing.
26. Remove seal (915) and guide (916) from transfer
housing.
27. Remove spring (911), valve (912), and o-ring (913)
from transfer housing.
28. Remove o-ring (913) from the valve (912).
29. Install new o-ring (913) on new valve (912).
NOTICE
Bullet tool 16D007 must be used or damage to the
seals will result when removing or installing items
onto the rod.