Johnson Service Bulletin #492 (1955) - Remote Control Cable Repair

Factory instructions dated August 20, 1955 for installing the tube, seal, and locknut assembly 376592 in Johnson remote-control cables. Includes the illustrated eight-step procedure, parts list, and special tools 304451 and 304479.

Green Johnson Service Bulletin letterhead
SERVICE BULLETIN #492August 20, 1955
INSTRUCTIONS - FOR INSTALLING TUBE, SEAL AND LOCKNUT
ASSEMBLY #376592 - REMOTE CONTROL CABLES
Factory parts diagram showing 376592 assembly, 376593 tube and trunnion, 304448 seal and 304449 lock nut, with service tools
Factory photo showing easy-out tool removing a broken cable tube

This replacement assembly #376592 includes the following -

1 #376593 Tube and trunnion assembly
1 #304448 Cork Seal
1 #304449 Lock nut
1 #304450 Instruction sheet

To make the replacement installation, the following tools are required -

1 1/4" - 40 NS bottoming tap - our part no. 304451
1 Easy Out - Size #2 - Our part #304479
1 Tap holder
1 7/16" open wrench

To make the installation -

  1. Pull control back far enough to clear.
  2. Grasp end of cable assembly firmly in vise.
  3. Insert easy-out into broken fragment of the tube. If "squashed" to prohibit entry of the easy-out, saw squashed end off to square - turn easy-out to left (counter clockwise) to remove broken fragment.
  4. Pluck small cork seal out of housing.
  5. Carefully install new cork seal.
  6. Turn lock nut up part way on threaded end of tube and trunnion assembly.
Superior Service Spells Satisfaction
Factory illustration of easy-out removing tube fragment

7. Insert and turn tube and trunnion assembly in until it comes to rest gently against the cork seal. The trunnion, which locates in the bracket on the motor, should line up at right angle to the gear rack at opposite end of the cable assembly to avoid necessity of "twisting" the cable when installing.

8. Draw up on lock nut to secure in this position.

Two factory photographs showing cork seal installation and tightening the locknut on remote control cable

Related parts and special service tools