AEM CAS Trigger Disc 308761 User Manual

Page 11 of 25 
 
  
Figure 17: Using prybar to remove cover 
 
Remove the 3 screws holding the CAS sensor onto the assembly as shown in figure 
18 as well as the rubber seal shown in figure 19. Make sure that you do not remove 
the screws in figure 20 because this may render the CAS sensor useless. 
 
Figure 18: Remove 3 screws holding sensor using ¼” flat screwdriver 
 
 
  

Page 12 of 25 
 
 
Figure 19: Remove seal from CAS assembly 
 
 
Figure 20: DO NOT REMOVE THESE SCREWS! 
 
  

Page 13 of 25 
 
Mount the assembly in a vise placing the two ears that stick out of the cover shown in 
figure 21 on the jaws being mindful of the plastic connector to the CAS sensor as 
shown in figure 22. 
 
Figure 21: Mounting CAS assembly in vise to separate from shaft 
 
 
Figure 22: Mounting CAS assembly in vise to separate from shaft 
 
  

Page 14 of 25 
 
Remove the shaft from the remaining half of the housing using a 3/8” pin punch as 
shown in figure 23. Figure 24 shows the sensor separated from the housing. 
 
Figure 23: Separation of shaft from housing using 3/8” pin punch and hammer 
 
 
Figure 24: CAS sensor removed from housing 
 
  

Page 15 of 25 
 
This step requires a lot of finesse or help from a friend to hold the shaft from falling 
off the vise. Mark the star socket relative to the shaft and remove the pin holding the 
star socket onto the shaft using a 1/8” pin punch as shown in figure 25. 
  
Figure 25: Removal of pin using 1/8” pin punch 
 
Remove the star socket with a ¼” flat screwdriver as shown in figure 26. Figure 27 
shows the star socket removed with the small rubber seal that is inside it. 
 
Figure 26: Removal of...

Page 16 of 25 
 
 
Figure 27: Star socket removed from CAS sensor 
 
This is another step that requires a little finesse or a friend. Remove the remaining 
bearing using a pair of pliers with flat jaws to have a firm grip on the shaft but be 
narrow enough to fit in between the collar on the shaft and the bearing. Hit the pliers 
with a mallet. Note how the shaft is placed into the vise in figure 28. Figure 29 shows 
the bearing removed from the shaft. 
  
Figure 28: Removal of bearing from shaft using...

Page 17 of 25 
 
 
Figure 29: Bearing removed from shaft 
 
Using the number 2 Phillips screwdriver remove the screws holding the CAS disc 
onto the shaft as shown in figure 30.  
 
Figure 30: Removal of 2 screws on CAS disc using number 2 Phillips screwdriver 
 
 
  

Page 18 of 25 
 
Figure 31 shows the shaft removed once the screws are removed. Mark the disc so 
that you can identify how it was mounted for future reference. Carefully remove the 
CAS disc from the sensor by rotating the disc in the direction of the large arrow 
relative to the locating pin so that it will pull directly up over the pin in the direction of 
the small arrow. 
 
Figure 31: CAS disc screws and shaft removed 
 
The original and AEM trigger discs must be aligned in the correct orientation...

Page 19 of 25 
 
 
Install the AEM CAS sensor disc (AEM PN 35-8761) as shown in figure 33. 
  
Figure 33: AEM trigger disc being installed 
 
Reinstall the shaft onto the CAS sensor as shown in figure 34 and replace the screws on 
the shaft with some thread locker as shown in figure 35. 
 
Figure 34: CAS sensor shaft reinstallation 
  

Page 20 of 25 
 
 
Figure 35: Screws for CAS shaft replaced 
 
Reinstall bearing as shown in figure 36. Next add some grease or spray lube onto the o-
ring that came off of the star socket that goes over the bearing and lightly hammer the star 
socket on a flat surface so that you are only hammering the shaft until the hole for the pin 
that holds the star socket lines up as shown in figure 37. A pin punch can be used to align 
the hole for the pin if it is slightly off. 
 
Figure 36: Bearing placement...