Cadillac 60 Series 1963 Shop Manual page 178

BRAKES
8-13
b. Cleaning and Inspection
1. Thoroughly wash all parts in clean alcohol.
NOTE: Use of gasoline, kerosene, anti-
freeze, or any other cleaner with even a trace
of mineral oil will damage rubber parts.
2. Use air hose to blow out all passages, ori-
fices, and valve holes. Air dry and place cleaned
parts on clean paper or lint-free cloth.
3. If slight rust is found inside front or rear
shell, polish clean with crocus cloth or fine emery
paper, washing clean afterwards.
4. Inspect front and rear shells for scratches,
scores, pits, dents or other damage affecting
rolling or sealing of diaphragm or other seals.
Small imperfections may be smoothed out with
fine crocus cloth.
5. Inspect power diaphragm for cuts, pin holes,
distortion or cracks.
6. Inspect all other parts for distortion, dam-
age, or excessive wear, and replace as necessary.
c. Assembly
Be sure all parts are clean before assembling
unit. Do not let grease or mineral oil come in
contact with any rubber parts.
Lubricate rubber parts of power piston group
with special lubricant included in service kit.
1. Place rear shell on bench with mounting
studs up. Place new bearing seal on Bearing Seal
Installer, J-9540, with plastic side of seal next to
Installer, and drive seal into shell until flange of
Installer contacts surface of shell adjacent to
seal, Fig. 8-14.
2. Apply special lubricant to outer diameter of
diaphragm plate hub and bearing surfaces of valve
plunger and to outer edge of poppet valve.
3. Insert valve and rod assembly in valve
housing, pressing valve plunger and poppet into
diaphragm plate hub, Fig. 8-12.
4. Align slot in diaphragm plate with groove in
valve plunger and insert plunger lock.
5. Install power diaphragm in groove of dia-
phragm plate.
6. Slide air filter and air silencer over valve
rod and guide into place in valve housing. Press
filter retainer on end of valve housing, using care
not to scratch or damage plastic housing.
7. Install dust guard retainer over studs on
rear shell.
W"
Bearing 5 4\
Seal I
lnstaller\ ?
J-9540 >
Jl - "
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/ I 4 TV
' * • • -
Rear
Shell
Iw
Fig. 8-14 Installing Bearing Seal in Rear Shell
8. Install dust guard over flange of dust guard
retainer and over flange of air filter retainer.
9. Place new vacuum check valve gasket on
front shell and install new check valve on front
shell. Press and turn valve clockwise to lock in
place, Fig. 8-12.
10. Place master cylinder in bench vise with
mounting flange up and place front shell of power
unit on master cylinder with mounting bolts
through holes in flange. Install four lockwashers
and nuts.
11. Install piston return spring in front shell,
with smaller end down.
12. Apply special lubricant to bearing seal in
rear shell and install diaphragm-assembly into
rear shell, guiding valve housing through bearing
seal.
13. Position rear shell and diaphragm assembly
on piston return spring.
14. Connect vacuum pump to check valve on
front shell of power unit and operate pump to ob-
tain at least 15 inches vacuum.
NOTE: If vacuum pump is not available, a
length of hose may be connected to car intake
manifold with engine operating at slow idle.
15. Install Power Unit Shell Separator, J-9504,
over mounting studs on rear shell and press rear
shell into front shell, aligning scribe marks so
that when shells are rotated into locked position,
scribe marks will line up. Rotate rear shell
clockwise to lock shells together, Fig. 8-11. Dis-
connect vacuum pump and remove Separator Tool.