BENDIX
POWER
BRAKE
5B-5
fluid.
Slide assembly to
bottom
of master cylinder
bore. Press and twist piston to
ease
cups past snap
ring
groove
into bore.
4. Dip new
rear
piston and spring assembly into
bore. Press and twist piston to
ease
cups past snap
ring
groove
into bore.
5. Press in against
rear
piston with round-end rod
to compress return springs. Do NOT use screw-
driver
or other sharp-edged tool since this
will
damage the push rod seat inside the piston.
Main-
tain
pressure on piston and use
Tru-Arc
pliers to
install
snap ring in
groove
inside bore. Make certain
that snap ring is securely seated in groove.
6.
Install
piston
stop
screw and new
O-ring
seal
in
port underneath bore. Torque screw with 3/8"
wrench
to 40 in. lbs.
7.
Install
new spring and check valve in both out-
let ports. Press new tube seat into port using spare
tube nut. Torque tube nut to 40 in. lbs. to be sure
tube seat is
bottomed
in port.
8. Remove master cylinder assembly from vise.
POWER PISTON-ASSEMBLE
(Fig. SB-4)
1. If
rear
vacuum seal was removed, place
rear
housing on bench with studs down and press new
seal
carefully into cavity in housing, plastic side
first,
using tool J 22677. (Fig. 5B-6) Use hands to
press seal about 7/16" below inner housing surface
or
until metal shoulder
bottoms.
DO NOT
CRACK
PLASTIC.
2.
Lubricate
outside diameter of diaphragm plate
hub,
bearing surfaces of the valve plunger, and outer
edge
of valve
poppet
with power brake lubricant.
3.
Insert control valve assembly into diaphragm
plate hub. Push on valve enough to insert the valve
plunger
stop
key. (Fig. 5B-3)
4. Assemble diaphragm on diaphragm plate, mak-
ing sure the inner bead of the diaphragm is seated
in
the
groove
in plate.
5.
Install
silencers over valve operating rod. Be
careful
not to chip the plastic.
6. Apply power brake lubricant to seal in
rear
housing and around hub of diaphragm plate.
Install
rear
housing over hub of diaphragm plate.
7.
Install
large felt air filter and
boot,
boot
onto
housing until it
bottoms.
8.
Install
clevis on the valve operating rod.
Press
INSTALLER
J
22677
\
SEAL
REAR
SHELL
,4-
J
Fig.
5B-6
Installing
Rear
Vacuum
Seal
brake
lubricant and install disc, button side first,
in
hub cavity of diaphragm plate.
10. Apply power brake lubricant to piston end and
shaft of hydraulic push rod and install firmly against
reaction
disc in diaphragm plate. DO NOT
LUBRI-
CATE
ADJUSTING
NUT END OF
PUSH
ROD.
POWER UNIT-ASSEMBLE
(Fig. 5B-2)
1. Coat front vacuum seal with power brake
lubri-
cant
and install in cavity of front housing, rubber
side toward master cylinder. Make certain rubber
portion
does
not separate from metal plate.
2.
Install
old master cylinder assembly or Tool
J-22805-01, on front housing. Torque
bolts
to 25
lb.
ft.
3.
Install
check valve and grommet in front hous-
ing if they were removed.
Lubricate
with alcohol
for easier assembly.
9. Coat all surfaces of reaction disc with power
Fig.
5B-7
Gauging
Push
Rod
Length
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