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Since the floating control valve is a com-
ponent part of this assembly and cannot be
disassembled from the push rod .
3. Place the air valve end of the air valve
push rod assembly into the tube of the primary
power piston .
Manually press the air valve
push rod assembly so that the floating control
valve bottoms on the tube section of the
primary power piston.
Installer Tool J-23175
can be used to manually press the floating
control valve to its seat.
4. Place the inside diameter of the floating
control valve retainer on the outside diameter
of floating
control valve Retainer Installer
J-23175. Place over the push rod so that the
closed side
of the retainer seats on the
floating control valve (figure 19).
With
Installer J-23175, manually press the retainer
and floating control valve assembly to seat in
the primary power piston tube (figure 20).
5. The filter element can now be stretched
over the push rod and pressed into the primary
power piston tube.
6. Using Snap Ring Pliers J-4880, place the
retaining ring into the groove in the air valve
(figure 17).
7. Position the rubber reaction bumper on
the end of the air valve .
NOTE :
Tolerances of component parts
affecting output of the power booster are
very critical .
To maintain correct power
brake output, the power piston assembly is
serviced as an assembly which includes a
pre-selected REACTION PISTON, PRIMARY
POWER PISTON, and SECONDARY POWER
PISTON. No gauging is required when power
piston service package is used .
8 . Assemble the primary diaphragm to the
primary support plate from the side of the
support plate opposite the locking tangs. Press
the raised flange on the inside diameter of the
diaphragm through the center hole of the
support plate .
Be sure that the edge of the
support plate center hole fits into the groove
in
the raised
flange
of
the
diaphragm .
Lubricate the diaphragm inside diameter and
the raised surface of the flange (that fits into
a groove in the primary power piston) with a
light coat of Delco Silicone Lube #5459912 (or
equivalent).
9. Mount Tool J-23101 (small diameter end
up) in a vise .
Position the primary power
piston so that the two radial slots in the piston
fit over the ears (tangs) of the tool (figure 15).
10 . Fold the primary diaphragm away from
BRAKES 5- 1 1
the outside diameter of the primary support
plate.
11 . Holding the edges of the support plate,
with the locking tangs down, place the primary
support plate and diaphragm assembly over the
tube of the primary power piston . The flange
on
the
inside
diameter
of
the
primary
diaphragm will fit into a groove in the primary
power piston .
12 . Grip the edges of the primary support
plate, press down, and rotate clockwise until
the tabs on the primary power piston contact
the stops on the support plate (figure 16) .
13 . Place the power head silencer on the
tube of the primary power piston so that the
holes at the base of the tube are covered.
14 . Apply Delco Silicone Lube #5459912 (or
equivalent) to the outside diameter of the
primary power piston tube .
15 . Remove the primary piston assembly
from Tool J-23101 and lay it aside .
16 . Assemble the secondary diaphragm to
the secondary support plate from the side of
the support plate opposite the locking tangs.
Press the raised flange on the inside diameter
of the diaphragm through the center hole of
the support plate. Be sure that the edge of the
support plate center hole fits into the groove
in the raised flange of the diaphragm . Apply a
thin coat of Delco Silicone Lube #5459912 (or
equivalent) to the inside diameter of the
secondary diaphragm and the raised surface of
the flange (that fits into a groove in the
secondary power piston) .
17 . Mount Tool J-23101 (with large diameter
end up) 'in a vise .
Position the secondary
power piston so that the radial slots in the
piston fit over the ears (tangs) of the tool .
Apply a light coat of Delco Silicone Lube
#5459912 (or equivalent) to the tube of the
secondary power piston (figure 11).
18 . Fold the secondary, diaphragm away from
the outside diameter of the secondary plate .
19 . Holding the edges of the, support plate
with
the
locking
tangs
down, place the
secondary
diaphragm
and
support
plate
assembly over the tube of the secondary power
piston .
The flange of the inside diameter of
the secondary diaphragm will fit into the
groove in the secondary piston .
20 . Grip the edges of the secondary support
plate, press down, and rotate counterclockwise
until the tabs on the secondary power piston
contact the stops on
the support
plate .
Fold the secondary
diaphragm
back
into
position on the
secondary
support
plate.
Leave the secondary power piston assembly
on Tool J-23101 in the vise (figure 13).
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