Re: The Cummins ISX / QSX Injector Casting Seat Cutter P/N: 416-6156-28

When changing injector sleeves on Cummins Series of engines, it's been standard practice to clean the casting seat area of the casting with a wire brush, included in our Injector Sleeve Removal & Installation Kit.

Many advanced machine shops, utilize our Casting Seat Cutter to insure proper Injector Sleeve Seating/Sealing prior to injector sleeve installation, in addition to brushing the casting clean.

This Casting Seat Cutter is found in our Casting Repair Kit, which is required for the rebuilding of a casting seat area that has developed cracks and/or has excessive casting wear.

Oversized (thick nosed) injector sleeves are not available and proper seating of the injector into the injector sleeve is a concern. Currently, with this Cummins ISX - QSX Series, it is NOT advised to remove any more casting material than suggested.

Suggested procedures to clean up any casting distortion and/or sealing serrations;

  1. In a machining center (seat & guide machine), using our casting seat cutter (416-6156-28) with the driving arbor (414-6114-10) and the appropriate guide bushing (416-6156-32), clean up the casting seat with a .002 to .003 cut (.005 maximum).
  2. While cutting, the seat cutter should be operated at about 60/80 RPM and should be kept well lubricated at all times with our Irontite Tap-O (468-9920-08) metal cutting fluid.

If removal of more casting material is required, then it's advised you install one of our Taper Threaded repair plugs in order to build up this casting seat area. These can be found in our Casting Repair Kit.

If there are any questions or concerns about these suggested procedures, please contact us. 


Rich Wengatz
Nat'l Sales Manager
Irontite Products, Inc. 319-377-9421





Complete 466E & 530E Series Kit with Toolbox 451-6773-00
Tap 437-5331-66
Guide Bushing 448-6771-40
Sleeve Removal Tool 448-6774-30
Casting Cleaning Brush 450-6951-05
Drive in Tool 448-6772-10


Optional Accessories and Consumables

7.3L Power Stroke Roll in Tool 448-6777-33
466E & 530E Roll in Tool 448-6774-63
7.3L Power Stroke Injector Sleeve ? Brass 448-6797-31
466E/530E Injector Sleeve ? Stainless Steel 448-6797-32

Sleeve Removal

(1) With the Tap (437-5331-66) and the Tap Guide Bushing (448-6771-40) thread the
upper end of the worn sleeve.

(2) Insert the sleeve remover (448-6774-30) threaded puller shaft of the removal tool
down into the old sleeve.  Continue to torque the shaft into the sleeve until the
shaft grips the sleeve tightly with the threads.   
(3) With the puller bridge (or cup) in place between the puller nut and the face of the
casting, and with the thrust bearing and the two thrust washers between the puller
nut and the puller bridge, continue tightening down the puller nut and pull out the
old sleeve as shown here.


Sleeve Installation

(1) Using the carbon steel casting brush (450-6951-05) clean out the inside of the
injector sleeve bore area, insure the casting is clean in the square cut corner for
proper sealing.   
(2) Apply Permatex Part # 6400026240 to the lower outer rim (not flat of casting or
flat of sleeve) and upper rim of sleeve, then use the sleeve drive in tool (448-6772-10)
and a hammer; drive the sleeve to the bottom of the casting.


Roll in Tool (Optional)

Use the roll-in tool to expand the upper end of the injector sleeve with either roll in tool,
(448-6777-33: 7.3L or 677463 466E & 530E) can be used in a seat and guide machine
(machining center), ½? hand drill at a speed of 50 RPM , or by hand tools.  Roll in the
upper end of the sleeve by rotating the arbor clockwise and letting the roll-in tool feed
itself into the injector sleeve till it bottoms.  The rollers in the cage assembly will expand
to a diameter within the specified limits. To remove the tool, reverse (counterclockwise)
the arbor rotation.  Keep the operating parts, rollers and arbor well oiled at all times.


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