Ratcheting End Plug Removal:
Note: Prior to removing the ratcheting end plug from the bore, measure and note how deeply it is installed. The replacement plug should be installed to this same depth to ensure proper line pressure control. The most accurate method is to insert a slide caliper rod through the hole in the plastic plug until it bottoms against the control valve. Bring the caliper end toward the plug until flush. This gives you the spring height adjustment from the plug to the valve. Record this measurement before removing the plug and duplicate this distance during reassembly to most accurately duplicate the spring compression setting. If your caliper will not pass through the hole, measure from the valve body casting surface to the outer face of the OEM plug and duplicate later.

The adjustment tool may be used during removal of either the OEM or Sonnax ratcheting end plug at the boost regulator valve bore.
Using the tool prevents breakage of the 2 anti-rotational tabs. The adjustment tool is provided in the F-119940-TL7 tool kit.
1. To remove the ratcheting end plug from the bore, gently insert the cam end of the tool into the valve body bore and over the end of the end plug.
2. Carefully rotate the tool counterclockwise until the tool seats fully against the plug and the anti-rotational tabs are enclosed fully in the cam.
3. Continue rotating tool to the left, until the end plug is removed from the bore. The tool has a 3/4″ hex head so a socket or wrench can be used.
Note: Before reaming any bores, inspect the main pressure regulator valve. 096, 097, 098 valve inner spools measure .6095″ OD. If your valve inner spools measure .5935″ OD, DO NOT CONTINUE. You have an 01M, 01N, 01P valve body and must order SC-01M/01N/01P and different tooling to continue with the repair.

Reaming Instructions:
Prep and Set-up
1. Remove all components from the bore.
2. Clean the bore thoroughly.
3. To align the main pressure regulator bore in the fixture follow the VB-FIX instructions. From tool kit F-119940-TL8: Use Jig F-119940-RJ5 and guide pin F-119940-GP6, then ream with reamer F-119940-RM6. To align the boost regulator valve bore in the fixture, follow the VB-FIX instructions. From tool kit F-119940-TL7: Use jig F-119940-RJ8 and guide pin F-119940-GP5, then ream with reamer F-119940-RM5.
Note: Extra attention should be paid to alignment and securing the valve body to the fixture on these bores. A very smooth action to insert and remove the guide pin after final securing is a must to provide easy, on-center reaming of these bores.
4. Soak the bore and reamer with cutting fluid (Mobilmet S-122, Lubegard Bio-Tap, Tap Magic™, etc). For best results, provide a continuous flow of water-soluble cutting fluid (i.e. Mobilmet S-122) during the reaming process.
5. Gently insert the reamer through the jig and into the bore until the cutting tip contacts the first bore to be reamed.
6. Select the correct sized socket to fit the square shank of the reamer, and attach it to a wobble/swivel socket drive.

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