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FINAL ASSEMBLY
1. Mount the front housing assembly in a
vise .
2. Position the power piston return spring
over the inset in the front housing.
3. Assemble the power piston group to the
rear housing by pressing the tube of the
primary
piston
through
the
rear
housing
bearing .
Press down until the housing divider
seats in the rear housing and the primary
power piston bottoms against the housing .
4. Hold the rear housing assembly (with
mounting studs up) over the front housing .
(Make sure that the piston rod retainer does
not dislodge from the secondary housing power
piston during this operation .) Position the rear
housing so that when the tangs on the edge of
the front housing are locked in the slots on the
edge of the front housing, the scribe marks on
the top of the housings will be in line .
5. Lower the rear housing assembly onto
the front housing.
The power piston spring
must seat in the depression in the face of the
secondary power piston. Check that the bead
on the outside diameter of the secondary
diaphragm is positioned between the edges of
the housing.
6. Continue to press down on the rear
housing and fit the slots in the appropriate
tangs on the front housing .
7 . To
facilitate
locking,
position
front
housing seal in the depression in the front
housing and apply a vacuum source to the
vacuum check valve in the front housing.
Using Tool J-23456, press down and rotate the
rear
housing
clockwise
into
the
locked
position .
Remove Tool J-23456; remove the
vacuum source . See Figure 9 .
BRAKES 5- 1 3
8. Place the silencer in the closed end of
the power head boot .
Push the boot retainer
over the boot. Stretch the boot over the push
rod and over the flange in the center of the
rear housing.
9 . Place the booster assembly in a padded
vise with the front housing facing up. Insert
the master cylinder push rod, flat end first,
into the piston rod retainer .
10 . Press down
on
the master cylinder piston
rod (with approximately 40-50 pound load) to
be sure it
is
properly seated .
11 . Remove the front housing seal to be sure
that no vacuum is in the power head while
gauging.
12 . Place gauge J-22647 over the piston rod
in a position which will allow the gauge to be
moved to the left or right without contacting
the studs (see figure 22).
NOTE :
The adjustment is correct if the
lower step contacts the piston rod and the
upper step clears the piston rod. ,
13 .If the push rod is not within specifi-
cations and the push rod does not have an
adjusting screw, a new service adjustable push
rod must be installed and adjusted to specifi-
cation . .If the push rod being checked has an
adjusting screw, adjust the push rod to specifi-
cation.
14 . Wipe a thin film of lubricant on the
inside diameter of the front housing seal and
position seal in the depression in the opening .
15 . Position the master cylinder assembly on
the front housing. Install the master cylinder
retaining nuts and tighten to 28 foot - pounds
torque .
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