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Published byMario Cutsforth
Modified over 2 years ago
Instructions for making plunger fork tool.
Drawing for the trigger assembly
499 Parts Drawing / Ordering Information
Tools you will need to disassemble a model 499
Remove shot tube from barrel shroud
Remove forearm screw
Remove top stock screw
Remove stock screws
Remove lever nut
Remove lever screw
Remove lever assembly
Remove trigger screws and nuts
Using a flat screw driver compress leg on safety so the safety can be removed
Remove safety from trigger and barrel shroud
Remove trigger assembly from barrel shroud
Using plunger fork insert into the barrel to compress plunger spring
Line up plunger fork on sides of the plunger casing so you can compress the plunger spring forward
Holding plunger fork handle against the table push down on the barrel shroud so anchor pin will release
Remove the anchor pin
Using a flat screw driver remove the plunger assembly
Using a steel rod 5/8” – ¾” in diameter put into the front of the barrel shroud to remove abutment
Tap rod with mallet until the abutment is loosened and will come out the back of the barrel shroud
Remove the abutment
You can test the magnet on the abutment before installing in the barrel by putting a bb on it to see if it will stay in place
I do this so you do not have to tear the gun apart again if the magnet is bad
Put abutment seal on the abutment plug
Seal goes on with flat side against plug and open end to the outside
Insert abutment with seal into the barrel, put a small amount of grease on seal to help slide in easier
Insert abutment with threaded side first into the barrel shroud
Using your rod push abutment all the way into the barrel shroud until it stops
Using a pointed punch re-stake the abutment into the barrel shroud. Be sure the abutment is all the way forward in the barrel shroud.
Before staking screw in shot tube and be sure the tube is right against the muzzle of the barrel.
Stake in place with a pointed punch or nail, make sure dimple is deep enough to hold abutment in place
To change plunger head remove the plunger pin
Remove plunger pin
Take off plunger head
Take off steel plunger washer
Remove plunger spring from plunger casing
Replace plunger spring on casing
Steel washer can go over the plunger head to make it easier to get back together
Insert plunger head with steel washer in plunger casing and line up the holes for the plunger pin
Compress the plunger spring so you can insert the plunger pin
Rebuilding trigger instructions are for trigger pull to the left
Remove safety from trigger casing
Remove trigger pin
Remove pawl spring
Remove trigger and trigger spring
New style post trigger is on left and I am holding the old style trigger with cut out for spring
Put trigger spring on post or in cut out. Use a small amount of grease on tip next to trigger
Old and new trigger with trigger springs
End of trigger spring must tuck into the notch inside the trigger sear right above thumb nail on left hand
Insert trigger with spring into trigger casing lining up the trigger spring into the sear notch
Line up trigger in trigger case so pin will go through
Insert pawl into the trigger casing the post on the pawl will tuck under the pointed end of sear
Wide side of pawl will be on the top side of the trigger casing
Line up pawl hole with trigger and trigger case
Tuck pawl spring under the pawl the short leg of spring is to the right and flat against the trigger casing
Holding the trigger, pawl and pawl spring together insert the trigger pin
Pin should go all way through to the other side
Top view of assembled trigger
Safety goes into trigger assembly with the leg opening up toward the top of the trigger assembly
When installing safety the pawl spring is under the safety
Push safety into assembly be sure the pawl spring is under the safety and the open leg is up
Push safety all the way into trigger assembly
See leg opening in correct position
Trigger is completely rebuilt and ready to insert into your gun
Installing plunger back into your gun
Use a small amount of grease on the plunger head and inside the back of the plunger casing. Insert plunger assembly into the barrel
The back on the plunger casing has a flat top and one with legs. The flat top goes to the top of the barrel shroud
Using your plunger fork align forks on both sides of the plunger casing and push forward
Plunger fork will compress plunger spring so anchor pin can be inserted
Compress plunger fork all the way forward and install anchor pin with the curve of the pin toward the back of the gun
Drop anchor pin into barrel shroud be sure the anchor pin is behind the plunger spring
Installing trigger into barrel. Remove safety from trigger assembly
Slide trigger assembly into barrel
Line up trigger with the trigger screw holes in the barrel shroud
Insert the front trigger screw into the barrel and trigger assembly it is easier to do by holding your trigger in place from the inside
Tighten screw a couple of threads to hold in place
Insert the back trigger screw into the barrel and trigger assembly
Tighten screw a couple threads to hold in place
Insert safety into safety hole
With the leg opening to the top of the barrel insert into barrel make sure the pawl spring is under the safety
Push safety into place
Safety should fit flat against barrel shroud
Be sure the leg is open inside the barrel shroud using a flat screw driver to spread it apart
Insert lever into barrel shroud and line up the screw hole
Insert lever screw
Tighten lever screw
Put nut on lever screw and tighten
You can test your gun to be sure it is working by cocking the lever and pulling the trigger. If trigger does not catch push safety forward and pull trigger.
Insert stock into barrel shroud
Line up screw holes with the barrel shroud
Screw in side stock screws on both sides of stock
Put nuts on trigger screws and tighten
Replace forearm, push into barrel shroud so holes will line up for the screws
Replace forearm screws and tighten
Screw top stock screw in place
Insert shot tube in barrel shroud
Tighten shot tube into the abutment
Shot tube should be tight against the barrel shroud
Parts of the trigger assembly
Trigger with post, trigger spring with small amount of grease
Trigger spring installed on the trigger
Inserting the trigger and trigger spring in the trigger casing, be sure to line up trigger spring in notch on the sear
Trigger in trigger casing with pin hole lined up
Inserting pawl into the trigger assembly
Line up pawl in trigger casing, insert post on pawl under the tip on the sear, wide side of pawl is closest to you
Pawl inserted in place
Line up pawl with the pin hole
Holding the trigger in place to insert the pawl spring
Tuck pawl spring under the pawl, short leg of spring is against the trigger, long leg is toward the left side of the trigger assembly
Pawl spring is in the correct position ready to insert the trigger pin
Close up of pawl spring in correct position
Inserting safety into trigger assembly
Safety is installed into the trigger assembly with the leg opening to the top of the trigger
Tuck pawl spring under the safety
Push safety into the trigger assembly
Safety is installed into the trigger assembly
View of trigger assembly from the front
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