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Power Brake Unit: Reassembly

  1. Apply silicone grease to rear housing oil seal and press into rear housing. Apply silicone grease to sliding surfaces of air valve assembly and install in power brake piston.
  2. Push air valve assembly into power brake piston and insert stopper key. DO NOT force installation and note installed position of stopper key.
  3. Install diaphragm on power brake piston by hand. Apply silicone grease to mating surfaces and ensure diaphragm is seated in piston groove by turning diaphragm.
  4. Apply silicone grease to reaction disc and install in power brake piston. Install power brake piston in rear housing.
  5. To complete reassembly, reverse disassembly procedure. Ensure piston return spring is properly installed in rear housing spring guide, and ensure that housing halves mate squarely before rotating halves into assembled position.
  6. Before installing power brake unit in vehicle, see POWER BRAKE PISTON ROD and PEDAL HEIGHT for adjustments.
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