Disassembly Of Booster Unit; Removal Of End Plate, Air Cleaner And Booster Piston; Removal Of Felt Retainer Felt, And Expander Ring; Assembly Of Booster Unit - Lincoln Continental 1964 Shop Manual

2-18
ASSEMBLY
1. Dip all parts except the master
cylinder body in clean FoMoCo
heavy-duty brake fluid.
2. Install the brake line fitting
and the stop light switch on the
cylinder and tighten them securely.
3. Install the 0-ring on the pis-
ton. Install the spring, seal, and
check valve assembly, seal, cup, and
piston in the cylinder bore (Fig. 18).
4.
Install the snap ring in the rear
end of the bore (Fig. 19).
DISASSEMBLY OF
BOOSTER UNIT
When overhauling the assembly,
always use a repair kit. If replace-
ment of the piston packing or dia-
phragm is necessary, use a piston
packing and diaphragm kit.
REMOVAL OF END PLATE,
AIR CLEANER AND
BOOSTER PISTON
1. Disengage the rubber boot from
the scalloped flange of the end plate,
and slide the boot back on the push
rod.
2. Scribe alignment marks across
the end plate and booster body. Re-
move six of the eight end plate at-
taching screws, leaving two opposite
screws~ Press down on the end plate
while removing the remaining two
screws
to
prevent the piston return
spring from expanding.
3. Scribe across the face of the
piston to register with the mark on
the end plate; then, remove the end
plate with the booster piston and
piston return spring.
FIG.
21-Retaining
Ring Removal
GROUP 2-BRAKES
(022)
PLATE
PISTON FRONT PLATE
~·~;~v·~:~r
SPRING~
VAlVE PlUNGER
RETAINER\
DIAPHRAGM
VALVE OPERA TJNG ROD
REACTION DISC
H1294-A
FIG.
22-Piston and Valve Disassembled
4. Slide the vacuum hose from
the booster piston and from the
vacuum tube on the inside of the
end plate. Separate the end plate
from the booster piston assembly by
sliding the valve rod and rubber
boot through the hole in the end
plate (Fig. 20).
5. Remove the screws, vacuum
tube and plate, and gasket from the
end plate. Remove the attaching
screws, air filter cover, and air filter
from the end plate (Part 2-1. Fig. 3 l.
REMOVAL OF FELT RETAINER.
FELT, AND EXPANDER RING
1.
Spring the felt retaining ring
sufficiently to disengage the ring
from the grooves in the bosses ,
m
the piston rear plate (Fig. 21).
2.
Remove the piston felt and
expander ring from the piston as-
sembly (Part 2-1, Fig. 3).
DISASSEMBLY OF BOOSTER
PISTON AND VALVE
1. Remove the six bolts and lock
washers from the piston front plate.
Lift off the piston rear plate, valve
rod, and plunger assembly. Remove
the leather piston packjng from the
piston front plate.
2. Remove the valve return spring.
poppet and diaphragm assembly,
poppet spring, and diaphragm sup-
port plate. Separate the poppet spring
retainer and the poppet diaphragm
from the poppet
I
Fig. 22).
3. Remove the rubber reaction
disc from the piston front plate. If
necessary, use
a
piece of rod having
a
smooth flat end to push the re-
action disc out of the piston plate.
4. Disengage the rubber dust
guard from the shoulder on the
pisttm rear plate. Slide the guard
bat:k
on the valve rod so that the
plunger can be pushed far enough
off its seat for cleaning and inspec-
tion.
Do not separate the valve operat-
ing rod from the valve plunger un-
less it is necessary to replace faulty
or damaged parts. To replace either
the valve operating rod or valve
plunger, hold the assembly with the
valve plunger down and inject al.co-
hol in the valve plunger through the
opening around the valve rod to wet'
the rubber lock in the plunger, then
drive or pry the valve plunger off
the valve rod.
With the plunger separated from
the rod, pull the rod out from the
rear side of the piston plate; then
slide the dust guard and rubber boot
from the ball end of the rod (Fig.
22).
ASSEMBLY OF BOOSTER UNIT
ASSEMBLY OF BOOSTER
PISTON AND VALVE
1. If the valve operating rod and
the
valve plunger were separated,
slide the rubber boot and the dust
guard over the ball end of the rod.
Insert the rod through the hole in