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Power Brake Booster: Reassembly

  1. Coat surface of reaction disc, dust seal lip, diaphragm-to-shell mating surface, power piston, valve plunger and oil seal with silicone grease. Install valve rod and plunger assemblies in power piston. Push down on valve rod and align groove in valve plunger with slot of power piston. Install retainer key and stopper.
  2. Install air filters, silencer and retainer in power piston. Slide vacuum piston and diaphragm over power piston. Connect diaphragm to power piston and vacuum piston. Ensure diaphragm is fully seated in groove. Install bearing, seal and retainer in rear shell. Slide rear shell over power piston.
  3. Install reaction disc in power piston with push rod. Install dust seal and front retainer in front shell. Install push rod. Install front shell into soft jawed vise. Install return spring into front shell.
  4. Using 2 screwdrivers, press rear shell downward and rotate shell clockwise until marks made on shells during disassembly are aligned. Install dust boot. Install brake master cylinder. Install brake booster. Fill reservoir with clean brake fluid and bleed brakes. See BLEEDING BRAKE SYSTEM  . Fill and bleed brake system. Check brake operation.
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