Frame-Mounted Booster—Exploded View - Ford 1964 F-100 Shop Manual

2-28
G R O U P 2-BRAKES
RUBBER GASKET
CONTROL VALVE CYLINDER
STOP WASHER
GASKET
DIAPHRAGM
CONTROL VALVE PISTON
- PISTON CUPS
CONTROL TUBE
CONTROL VALVE BODY
SPRING
SEAL
AIR INLET TUBE
AND COVER
SNAP RING -%V-5\
BLEEDER SCREW
PUSH ROD
LEATHER SEAL
BOOSTER BODY
SEAL
HOOK BOLT
BOOSTER
PISTON
FIG. 22—Frame-Mounted Booster—Exploded View
(Fig. 22). Place a wrench on the
milled flats and tighten the cylinder
securely.
2. Thread the lock nut on the
hydraulic cylinder to the limit of the
threads. Position a n e w lock nut seal
between the two sections of thread
on the hydraulic cylinder.
3. Place the end plate on two
wooden blocks with the hydraulic
cylinder side of the end plate up.
Press the push rod leather seal into
the end plate with the lip of the
leather seal toward the hydraulic
cylinder side of the end plate.
4. Dip the control valve piston
seals in heavy duty brake fluid, as-
semble the seals on the piston with
the spacer between the two seals,
and secure with the C-type retainer
(Fig. 22). T h e lip of each piston
should point toward the retainer end
of the piston. Insert the piston as-
sembly into the control valve cylin-
der from the rear side of the cylin-
der. Install the stop washer at the
front end of the cylinder against the
piston, and secure in place with the
snap ring.
5. C l a m p the end plate in a vise
at one of the bolt flanges. Place a
new rubber gasket over the threaded
end of the control valve cylinder.
thread the cylinder into the end
plate, and tighten securely with a
l'/s-inch socket.
6. T o assemble the push rod seal
cup parts (Fig. 22), insert the push
rod through the leather seal at the
rear side of the end plate. T h e rod
will hold the parts in alignment as
they are installed. Install the stop
washer with the chamfered side
toward the end plate, the seal cup
with the lip of the cup away from
the stop washer, the seal retainer
with the flanged end next to the cup,
and the spacer with the chamfered
end next to the cup. Install the spring
over the seal retainer and against the
flat side of the spacer. Place the
retainer washer against the spring.
and compress the spring until the
washer i s to the inner side of the
snap ring groove. Install the snap
ring in the groove, then remove the
push rod. Install a n e w cylinder end
seal.
7. Fabricate a v a c u u m piston as-
sembly ring by cutting a 1-inch sec-
tion from an old cylinder shell of
correct size. Place the assembly ring
(Fig. 24) on the bench and assemble
the vacuum piston parts in the as-
sembly ring, installing the larger di-
ameter piston plate with the cham-
fered side of the hole up, the leather
piston packing with the lip of the
packing up, the seal ring, and the
small diameter piston plate with the
chamfered side of the hole down.
8. Cut the wicking to the required
length, and assemble i t against the
inner face of the piston packing lip.
9. Position the expander ring in-
side the wicking, with the gripper
points up and the notch at the loop
end of the expander ring under the