Service Manual User Manual

REMOVING BRAKE VALVE FROM
VEHICLE AND SEPARATING SECTIONS
(Refer to Figures 1 & 3)
Remove Brake Valve from vehicle by disconnecting
necessary fluid lines, disconnecting push rod and
removing mounting bolts. Drain fluid from assembly.
Separate Master Cylinder Section from Power Assist
Section by removing three cap screws and three
lock washers.
CONNECTING SECTIONS AND
MOUNTING BRAKE VALVE ON VEHICLE
(Refet to Figures 1 & 3)
Attach Master Cylinder Section to Power Assist
Section with three cap screws and three lock washers.
Torque 29.8-36.6 Nm (22-27 lbs-ft).
Install unit on vehicle and connect fluid lines. Connect
push rod. Bleed system of air. Tighten fittings if leaks
occur. Make several applications to be sure brake valve
is working properly. NOTE: All fittings must be
inspected for leaks and tightened if leaks occur.
MASTER CYLINDER DISASSEMBLY
(Refer to Figures 1 & 4)
Remove filler plug (15) and gasket (14) from housing
(2).
Drain fluid from unit before disassembling.
Place master cylinder section in a soft jawed vise in
a vertical position with end plug (11) facing up.
Remove adapter (13) and gasket (12) from end plug
(11). NOTE: Not all models use adapter (13) or
gasket (12).
Remove end plug (11) from housing (2).
CAUTION
End plug (11) is under tension of spring (7).
Remove check valve (8), seat (9) and o-ring (10)
from end plug (11).
Remove spring (7) from housing. Remove retainer
(6) from spring (7).
Use a wooden dowel to push cup (5), piston
assembly (4) and piston assembly (3) out of end
plug (11) end of housing (2). NOTE: Be careful not
to scratch or mar housing bore.
Remove retaining ring (1) from housing (2).
1.
2.
1.
2.
cap screws
lock washers
MASTER CYLINDER
SECTION
POWER ASSIST
SECTION
FIGURE 3
1.
2.
3.
4.
5.
!!
!!
!
6.
7.
8.
9.
MASTER CYLINDER ASSEMBLY
(Refer to Figures 1 & 4)
Use only automotive brake fluid in Master Cylinder
Section.
LUBRICATE ALL RUBBER COMPONENTS FROM
REPAIR KIT WITH CLEAN TYPE FLUID USED IN
THE SYSTEM.
Clean all parts thoroughly before assembling.
Install new retaining ring (1) in housing (2).
Carefully install new piston assembly (3), new piston
assembly (4) and new cup (5) in end plug (11) end
of housing. Note direction of piston assemblies (3 &
4) and cup (5). NOTE: Be careful not to scratch
or mar housing bore.
Install new retainer (6) on spring (7). Install spring
(7) in housing, retainer end first.
Install new o-ring (10), new seat (9) and new check
valve (8) on end plug (11). Install end plug (11) into
housing. Torque end plug (11) 61.0-81.4 Nm
(45-60 lbs-ft).
Install new gasket (12) and adapter (13) in end plug
(11). Torque adapter (13) 47.5-54.2 Nm (35-40 lbs-ft).
NOTE: Not all models use gasket (12) or adapter
(13).
Remove master cylinder section from soft jawed
vise.
Install new gasket (14) and filler plug (15) on hous-
ing (2).
1.
2.
3.
4.
5.
6.
7.
8.