Disc Brake System: Service and Repair

Power Brake Unit Installation:

Removal

1. Remove two nuts holding master cylinder to power unit and position it away from power brake unit. Do not disconnect hydraulic brake lines; be careful not to bend or kink lines.
2. Disconnect the vacuum hose from the vacuum check valve on the front housing of the power unit. Cover vacuum hose to prevent entrance of contaminants.
3. Loosen the four nuts that hold the power brake unit to the dash.
4. Disconnect the power brake push rod from the brake pedal. Do not force push rod to the side when disconnecting.
5. Remove the four nuts from the mounting studs which bold the power unit to the cowl.
6. Remove the power brake unit and clean prior to disassembly.

Installation

1. Mount power brake unit to cowl and loosely install the four nuts.
2. Connect power brake unit push rod to brake pedal.
3. Tighten power brake unit nuts to specified torque.
4. Connect vacuum hose to vacuum check valve.
5. Connect master cylinder to power brake unit and torque nuts to 24 ft.lbs. (33 N.m).
Be sure brake lines are properly routed with adequate clearance to adjacent components. Check lines for cracks or leakage.
Always replace the vacuum check valve and grommet when replacing or overhauling power brake unit.
5. Check brake operation, adjustment and stoplamp switch adjustment.