These are the
steps to install a cable and mast for a Delco Power unit that has a
mechanical stop. These units were used by GM from 1990-2002, not all
Delco units used a mechanical stop. To know if you have this
style, your unit will shut off on its own if the cable that moves the
mast is broken or not installed, if it shuts off after about 8 seconds
on its own then these are the instructions on installing a cable and
mast.
1. Remove the power unit from
the car, take it to your work bench.
How to Remove the Mast:
A through E below.
A.
Extent the mast and unscrew the tip from the solid rod section of the
mast.
B.
Drill off all the rivets that are used to hold the case together.
Then important, note with a magic marker, the position the storage tube is mounted
onto the gear case before you remove it, this way when we put it back
together we can do so correctly and it wont be 180 degrees out. Then remove the clips on the outer
portion of the case, then split the case.
C. Now take the metal storage tube
that the mast is in and remove it from the split gear case.
D.
Now unscrew the
upper black plastic insulator from the top of that storage tube
housing using a 14mm 12 point socket, then pull the tube sections of the
mast out of
that storage tube.
E. Now remove all of the remaining cable and hook
from that split gear case.
... Important, ... pay attention to how that hook is mounted into the drum, this way you
will know how to install the new hook when it comes time to do so.
First timers I would suggest after removing that hook, practice a
reinstall right after you remove it so when it comes time to install it
for real you know exactly how to do so. You will see why later.
How to Install the Mast
and cable:
First this needs to be
done.
Note: Before you
install the new cable you need to make sure the fish hook has the
correct curve to it so that it lays into the drum centered, like photo
B. If you do not do this it can break the cable at the fish hook when
installing or lessen the life of the cable.
How to do this, dry fit the
hook like what is shown in photo A, lay the hook on top of the drum and
check the curvature of the hook, note that the fish hook is not going to
lay into the center of the drum correctly.
Take 2 pliers and gently bend the fish hook
so it ends up looking like photo B. Never touching the plastic cable as
you do so. Doing this will extend the life of the cable. Do this before
you install the cable into the drum.

This is how the hook should
look like when installed. It needs to be centered in the drum and lay
naturally between the drum walls.
Now How to Install the Mast
and cable:
1 threw 7 below.
1. Now without either the mast
sections and no cable installed in the gear case, put cases back
together and put ALL clips in place. Just the case
with no metal storage tube attached to it. We are about to time the unit
so it runs correctly.
2. Now take the power unit
back to your car, FIRST turn your key on and the radio on, THEN plug the
power unit back into the power plug and let the power unit run until it
shuts off by its self. Should shut off on its own in about 8
seconds. Just let it lay in your trunk when doing so.
3. Now after the power unit
shuts off, THEN unplug it from the car. AFTER you unplug the power unit
now turn the key and radio OFF. Take the gear case back to your
bench.
4. Now GENTLY split the
cases and don't move a thing and only install the new cable and
fish hook and put the cases back together along with the metal storage
tube. DO NOT move anything when you
do this including the drum. If you move any thing your timing will
be off. At this point the cable should be
sticking out the top of the storage tube when your done.
5. Now take the power unit
back to your car, make sure that the radio & key is off, You want to
plug in the unit ONLY LONG ENOUGH to draw the cable in until the
rod portion of the cable is about to go in. DO NOT RUN THE UNIT ANY
LONGER OR YOU WILL DESTROY THE UNIT. You will run it only for
about 2 to 3 seconds.
6. Now install the Tube
sections of the mast into the top of the storage tube along with the upper black
plastic insulator that holds the Mast in, then screw the tip on.
7. Now take the power unit
back to the car and plug it back in, it should run down the rest of the
way, if so turn the radio back on and it should run all the way up. If
it runs correctly install the power unit back into the car. If it
doesn't work correctly, start over with step 1