Very difficult to get this right.
The pca posts were not tapped in the first place. The nut was simply added and it self tapped! If it doesn't line up then you will cross thread and poof, no more lock down.
The best you can do is try but only until just tight. Close it up and test the unit. Tighten some more if it did not power up due to a bad connection. Repeat.
If, according to the manual, the nuts do not tighten then switch to a smaller diameter nut. Not a very helpful suggestion. If smaller nuts are not available then take some vinyl tubing of the same type everyone uses for the pinch roller in the card readers. Cut a section slightly shorter then the amount of post that sticks out the PCA when it is in place (with the nuts removed). Place the tube over the post when the PCA is in place. Replace the back and screw together the case. This may take a few attempts to get the tube length correct. So cut it long, then shave off some. You are trying to make a pressure fit that relies on the bottom case posts without over stressing the case posts themselves.
What you have created is a pressure fit that relys on the bottom case screws to press against the vinyl tubes which then press down on the PCA (what the nuts used to do) and complete the connection.
It should look similar to this:
Hope this helps.
Geoff
p.s. In repair attempts on two of these types I have resorted to the above repair. I am either clumsy or this really was a bad design not conducive to more then one or two removals. Thus necessitating the newer design about one year later.
Edited: 3 May 2010, 11:15 a.m.
