a. Disconnect parking brake cable from parking brake lever.
b. Remove round head screws from both brake access plates and remove
access plates.
c. Remove deck plate fasteners and deck plate.
3. Disconnect brake pedal linkage from power booster by removing linkage
locknuts and capscrews.
4. Place rags under booster and master cylinder assembly. Disconnect all hoses
and pipes from booster and master cylinder.
5. Plug hoses, pipes, and booster ports to prevent entry of dirt, water or other
contaminants.
6. Remove hardware securing power booster to bracket and remove booster
assembly.
Do not carry brake booster by accumulator, allow brake booster to
fall on accumulator or expose brake booster to heat or flame. It contains high
pressure gas and can leak under pressure and explode if heated.
1.7.2 Repair
Repair of the power booster/master cylinder assembly is not recommended. If faulty,
replace entire unit.
1.7.3 Installation
1. Position power booster assembly on bracket and secure booster with its
mounting hardware. Tighten capscrews to 30 ft-lbs torque.
2. Bleed air from master cylinder.
a. Fill reservoir with DOT 3 brake fluid.
b. Using two plastic or rubber tubes, each approx. 5 inches long, place one
end of each tube into one of the master cylinder ports and place other
end in reservoir.
c. Move booster piston back and forth until no more bubbles appear.
d. Remove tubes and connect brake lines to master cylinder.
3. Connect brake lines to master cylinder and tighten.
4. Connect fittings to power booster and tighten.
5. Bleed air from Hydro-boost unit as follows:
a. Fill pump reservoir.
b. Crank engine for several seconds with coil wire or fuel pump wire
disconnected. DO NOT START ENGINE.
c. Check fluid level and add if necessary.
CHAPTER 3 OVERHAUL AUGUST 31, 2008
1 GENERAL REPAIR PAGE 13
M100 Tow Tractor Manual No. 46052
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