PART 2-2 -Brake System
2-25
from the switch body.
2.
Loosen the tube nut connecting
the primary (front brake) system in-
let tube at the top of the pressure dif-
ferential valve assembly and discon-
nect the tube.
3.
Disconnect the primary system
left front brake outlet tube from the
top side of the pressure differential
valve assembly.
4.
Disconnect the primary system
right front brake outlet tube from the
top side of the differential valve as-
sembly.
5.
Disconnect the secondary (rear
brake) system inlet tube at the lower
side of the pressure differential valve
assembly.
6. Disconnect the secondary sys-
tem rear brake outlet tube from the
lower side pressure differential valve
assembly.
7.
Remove the screw retaining the
pressure differential valve assembly
to the frame side rail and remove the
valve assembly.
8. On disc brake equipped vehicles,
place the pressure differential valve
assembly and mounting bracket in a
vise.
Loosen the proportioning valve
tube nuts at the differential valve
and at the proportioning valve. Re-
move the proportioning valve from the
mounting bracket.
9. If the differential valve is to be
replaced, remove the brake warning
lamp switch and install the switch in
the new differential valve. The pre-
sure differential valve assembly and
the brake warning lamp switch are
separate units and each is serviced
as a separate assembly only.
INSTALLATION
1.
On disc brake equipped vehicles,
connect the proportioning valve inlet
and outlet tubes to the proportioning
valve and differential valve bodies.
Tighten the tube nuts to specification.
2.
Mount the pressure differential
valve assembly on the frame side rail
and tighten the attaching screw.
3.
Connect the rear brake system
inlet tube to the pressure differential
valve assembly and tighten the tube
nut to the specified torque (Refer to
Part 2-3).
4.
Connect the rear brake system
outlet tube to the pressure differen-
tial valve assembly. Tighten the tube
nut to the specified torque.
5.
Connect the front brake system
inlet tube to the pressure differential
valve assembly and tighten the tube
nut to the specified torque.
6. Connect the right front brake
outlet tube to the pressure differential
valve asssmbly. Tighten the tube nut
to the specified torque.
7.
Connect the left front brake out-
let tube to the pressure differential
valve assembly. Tighten the tube nut
to the specified torque.
8. Connect the shell-wire connector
to the brake warning lamp switch.
Make sure the plastic lugs on the con-
nector hold the connector securely to
the switch.
9. Bleed the brakes and centralize
the pressure differential valve.
BOOSTER NUT
REMOVAL
1.
Working from inside the vehicle
below the instrument panel, discon-
nect the booster push rod link from
the brake pedal assembly. To do this,
proceed as follows:
Disconnect the stop light switch
wires at the connector. Remove the
hairpin retainer. Slide the stop light
switch off from the brake pedal pin
just far enough for the switch outer
hole to clear the pin, and then lift the
switch straight upward from the pin.
Be careful not to damage the switch
during removal. Slide the boosterpush
rod and the nylon washers and bush-
ing off the brake pedal pin (Fig.
23).
2.
Open the hood and remove the
master cylinder from the booster. Se-
cure it to one side without disturbing
the hydraulic lines. It is not necessary
to disconnect the brake lines, but care
should be taken that the brake lines
are not deformed. Permanent defor-
mation of brake lines can lead to tube
failure.
3.
Disconnect the manifold vac-
uum hose from the booster unit. If
the vehicle is equipped with an auto-
matic transmission disconnect the
transmission vacuum unit hose.
4.
Remove the four bracket-to-dash
panel attaching nuts (Fig. 23). Re-
move the booster and bracket assem-
bly from the dash panel, sliding the
push rod link out from the engine side
of the dash panel. Remove the four
spacers.
5.
Remove the push rod link boot
from the dash panel.
INSTALLATION
1.
Install the push rod link boot in
the hole in the dash panel as shown
in Fig. 23. Install the four spacers on
the mounting studs.
2.
Mount the booster and bracket
assembly to the dash panel by sliding
the bracket onto the mounting studs
and the push rod link in through the
hole and boot in the dash panel. In-
stall the bracket-to-dash panel attach-
ing locknuts(Fig. 23).
3.
Connect the manifold vacuum
hose to the booster. If the vehicle is
equipped with an automatic trans-
mission connect the transmission
vacuum unit hose.
4.
Before installing the master cyl-
inder, check the distance from the
outer end of the booster assembly
push rod to master cylinder surface.
Turn the screw in or out to obtain the
specified length. Refer to Part 2-1,
Section 2, Power Brake Master Cyl-
inder Push Rod Adjustment. Install
the master cylinder and torque the
attaching nuts to specifications.
5.
Working from inside the vehicle
below the instrument panel, connect
the booster push rod link to the brake
pedal assembly. To do this, proceed
as follows:
Install the inner nylon washer, the
booster pushrod, and the bushing on
the brake pedal pin. Position the
switch so that it straddles the push
rod with the switch slot on the pedal
pin and the switch outer hole just
clearing the pin. Slide the switch com-
pletely onto the pin, and install the
nylon washer as shown in Fig. 23.
Be careful not to bend or deform the
switch. Secure these parts to the pin
with the hairpin retainer. Connect
the stop light switch wires to the con-
nector, and install the wires in the
retaining clip.
BRAKE PEDAL—MANUAL
SHIFT TRANSMISSION
REMOVAL
1.
Disconnect the clutch pedal-to-
equalizer rod at the clutch pedal by
removing the hairpin type retainer
and bushing (Figs. 22 and 23).
2.
Disconnect the stop light switch
wires at the connector.
3.
Remove the spring retainer.
Slide the stop light switch off the brake
pedal pin just far enough for the
switch outer hole to clear the pin, and
then lift the switch straight upward
from the pin. Be careful not to dam-
age the switch during removal. Slide
the master cylinder or booster push
rod and the nylon washers and bush-
ing off the brake pedal pin (Figs.
22 and 23).
4.
Remove the hairpin type retain-
er and washer from the clutch and
brake pedal shaft. Remove the clutch
pedal and shaft, the brake pedal, and
To Next Page
Loading...
