Quoted from aeonblack:
I have: Flipper, washer, plug, washer, bushing, sleeve. Is that not correct? Should the bottom washer be below the bushing instead of between the bushing and plug?
This is from Steve Ritchie (apologies...I don't remember the original poster in this thread - stacking order is in the third paragraph). I did this to mine and have not had a single ball stuck since (couple hundred games):
Remove all 6 balls from the lower trough. Carefully lift the playfield and stand it up against the backbox making sure that it is stable, (check the manual) then loosen the upper right flipper shaft clamping block (on the bottom of the wood playfield) with a 5/32” hex (Allen) wrench allowing a bit of rotational and up and down movement of the flipper shaft. Use your manual to locate assemblies if you don’t know the names of the parts I’m mentioning.
Lay the playfield back down on the playfield support brackets. Pull the playfield toward the front of the game until the round rubber feet on the playfield support brackets are securely in the hand protector trough. Carefully prop up the rear of the playfield with an 18” long piece of 2X4 or other prop using the cabinet floor and a blank spot on the bottom of the playfield so that the entire flipper stack is visible and within your reach from the right side of the game.
Slowly pull the loosened flipper shaft upward, freeing up the different parts of the flipper stack, and removing them carefully. Remove the flipper shaft pulling upward. When you have the flipper removed from the game, slide the ironing board on the shaft, then slide the new metal washer up the shaft under the ironing board, then the fat white nylon bushing, then the clear plastic bushing onto the shaft, and feed the lower tip of the flipper shaft through the plastic upper playfield and back into the flipper bushing on and through the lower wood playfield. Guide the ironing board into the flipper-shaped hole in the plastic upper playfield. Remove the playfield prop and lower the rear of the playfield onto the playfield cabinet rails. Carefully lift the playfield and stand it up against the backbox while holding the upper right flipper in place. Feed the flipper shaft through the flipper clamp block and tighten just enough so that you can still rotate and move the flipper up and down in the clamp block.
Next, the goal is to have zero up and down play in the upper right flipper assembly. Locate the plastic flipper body over the ironing board and aligned the flipper with it on all sides. Push down on the flipper and up on the clamping block until there is zero up and down movement of the flipper. Tighten the hex screw with the 5/32” Allen wrench lower the playfield back into the company and check for flipper alignment and up and down end play. The ball will no longer stay stuck behind the upper right flipper. There will still be enough up and down play due to the flexiblity and softness of the plastic parts in the stack.