July 16, 2004 6881094C28-D
8-22 Disassembly/Reassembly Procedures: Ensuring Radio Submergibility
8.10.9.4 Frequency Switch, Toggle, and On/Off/Volume Control Switch
To replace the frequency switch, toggle, and On/Off volume control switch:
1. Referring to Section “8.8.1 Separate the Casting and Housing Assemblies” on page 8-12,
remove the housing assembly (2) from the radio.
2. Remove the speaker retainer screw (23).
3. Remove the speaker retainer (36).
4. Install the universal connector cover (5) (see page 8-9). This will hold the universal connector
in place when the controls flex is removed.
5. Disconnect the controls flex (18) from the universal connector by disengaging the spring tab
on the backer from the catch features on the housing.
6. Disconnect the controls flex (18) 22-pin connector from PTT area of the housing
assembly (2).
7. Referring to Section “8.6 Frequency Knob” on page 8-10 and Section “8.7 Volume Knob” on
page 8-11, remove the frequency knob, frequency insert, secure lever, lightpipe, volume
knob, volume insert, and O-ring.
8. Using a thin, flat-bladed screwdriver, unsnap the left snap of the controls bracket assembly
(34) first, then unsnap the right snap.
9. Remove the controls bracket assembly (34).
10. Remove the controls seal (35).
11. Disassemble the controls bracket assembly (34) by disengaging the snaps to remove the bot-
tom bracket (33).
12. Replace the switch that leaks by following the unsoldering and replacement instructions con-
tained in the new switch’s instruction sheet.
13. Reassemble the controls bracket assembly (34) by snapping the two brackets together.
14. Install the controls seal (35).
15. Reassemble the controls bracket assembly (34) into the housing (2) by snapping in the right
side of the bracket first, then snapping in the left side.
16. Referring to Section “8.6 Frequency Knob” on page 8-10 and Section “8.7 Volume Knob” on
page 8-11, install the frequency knob, new frequency escutcheon, new frequency insert,
secure lever, lightpipe, volume knob, new volume insert, and O-ring.
17. Reconnect the controls flex (18) to the universal connector and the PTT area of the housing
assembly (2). Make sure the spring tabs on the backer fully engage the catch features on the
housing.
18. Install a new main seal O-ring (55) around the casting assembly (51).
19. Reassemble the housing assembly (2) to the radio.
20. Inspect the main seal (55) for proper seating. Observe carefully to ensure that the main seal
O-ring is not pinched between the housing (2) and the casting (51).
Removing the controls flex without installing the universal
connector cover may compromise the universal connector.
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a u t i o
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