July 16, 2004 6881094C28-D
8-12 Disassembly/Reassembly Procedures: Radio Disassembly
8.8 Radio Disassembly
This section contains instructions for disassembling the radio.
8.8.1 Separate the Casting and Housing Assemblies
To separate the housing assembly from the casting assembly:
1. Turn off the radio by rotating the On/Off/Volume control fully counterclockwise until you hear
a click.
2. Remove the antenna, the battery, and the universal connector cover or any accessory con-
nected to the radio.
NOTE: It is not necessary to remove the volume knob (6) and insert (7) or frequency knob
(13) and insert (11) to service the casting assembly. However, if any top control is
suspected, then the knobs and inserts should be removed prior to removing the
casting assembly (51) from the housing assembly (2). Refer to Section “8.1
XTS 5000 Exploded View (Partial)” on page 8-1 and Section “8.7 Volume Knob” on
page 8-11.
3. With the back of the radio facing upward, insert the
6685833D01 special tool at the bottom of the radio between
the housing assembly (2) and the two housing tabs on the
casting assembly (51) until the special tool’s latch engages
the two battery tabs on the casting assembly. With the latch
engaged, gently pull the casting away to remove it from the
housing (do not use a prying motion). Making sure that the
antenna bushing has cleared the hole in the control top,
carefully lift the casting assembly clear of the housing
assembly.
4. While holding the casting assembly (51) in one hand and the housing assembly (2) in the
other, unplug the 40-pin connector, on the controls flex assembly (18), from the VOCON
board (44).
NOTE: This can easily be done using the thumb of the hand holding the housing assembly.
8.8.2 Disassemble the Casting Assembly
To disassemble the casting assembly:
1. Put the housing assembly aside.
2. Remove the main seal (55) from around the casting assembly (51).
3. If you are disassembling a model I radio, skip to step 6; if you are disassembling a model II or
III radio, continue this procedure.
4. With the front of the radio facing upward, unplug the 22-pin connector for the LCD module
(38) (located to the right and above the LCD module). Lift the LCD module (38), with display
locator pad (39), up and off of the two locator posts on the casting (51).
5. Remove the LCD module (38) and put it aside.
6. Unplug the 22-pin connector for the keypad flex (37) (located to the left and above the LCD
module area).
7. Pry upward on all four control locking clips (40) for the VOCON board shield assembly (41),
alternating diagonally across the shield. Remove the VOCON board shield assembly, with
keypad flex assembly (37) (models II and III only) and clips still attached, from the casting.
8. Lift the VOCON board (44) up and away from the casting.
6685833D01 Tool
Battery Tabs
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