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Brake Booster - BENDIX Hydro-Boost: Reassembly

  1. Be sure that all parts are absolutely clean. Lubricate all seals and metal friction points with power steering fluid. Install tube seat. See Fig 1.
    Fig 1: Installing General Motors Tube Seats Lightly tap in tube seat with hammer.
    G30368
  2. Install "O" ring, spool valve plug and retaining ring. Coat piston seal and bore with clean power steering fluid and place seal in bore. Lip of seal must face away from master cylinder mounting flanges.
  3. Lubricate input rod end, new input rod seals, and seal installer tool with clean power steering fluid. Slide seals on tool with lip of cups toward open end of tool. See Fig 2.
    Fig 2: Installing Input Rod Seals Lubricate all parts and tools with power steering fluid.
    G30369
  4. Slide tool over input rod end and down to second groove. Slide forward seal of tool and into groove. Assemble other seal in first groove. Make sure both seals are seated.
    NOTE: Diesel models use only 1 seal on input rod.
  5. Lubricate piston and piston installation tool with clean power steering fluid. Hold the large end of the tool against the piston and slide the tool and piston into the piston bore and through the piston seal.
  6. Remove tool. Install return hose "O" ring fitting. If accumulator valve was removed, install new seat in valve bore by installing 2-function valve, which forces seat to bottom in bore.
  7. If removed, insert new dump valve over the 2-function valve. Ensure dump valve plunger is held in place until installation is complete. Insert spool valve spring and valve assembly into bore.
  8. Extend power piston lever to accept sleeve on spool valve. Slide lever pins into slot in sleeve. Install new seal in groove in housing cover. Join booster housing and cover and secure with 5 screws.
  9. Install output rod, spring and new spring retainer. Install new baffle and spring retainer by pushing in on it with a 7/8" socket. Lubricate accumulator seal with clean power steering fluid. Install seal and accumulator in housing.
  10. Place retaining ring over accumulator. Place retaining cap tool over accumulator. Using a "C" clamp, compress accumulator straight in. Snap retaining ring into the housing groove, and remove "C" clamp and tool.
    Fig 3: Installing Input Rod Assembly into Booster
    G30370
  11. Position mounting on booster. Tab on inside diameter of large hole in bracket should fit into slot in threaded portion of booster hub.
  12. Install new bracket nut with staking groove outward on the threaded hub of booster. Using deep socket and a torque wrench, tighten nut to 110 ft. lbs (150 N.m).
    Fig 4: Bendix Hydro-Boost Assembly
    G200072
  13. Using a hammer and punch, stake the nut in place. Assemble boot (if used) on pedal rod. Assemble new grommet in groove near end of pedal rod. Moisten grommet with water and insert grommet end of the pedal rod into the input rod end of the booster housing.
  14. Push on end of pedal rod to seat grommet. Slide the boot on the pedal rod and assemble the large end of the boot onto the hub of the power section.
TOOL NUMBER

Application GM No.
Retainer Shearer J-24569
Retaining Cap Tool J-26889
Input Rod Seal Tool
Rear Drum Models
Gasoline J-24553
Diesel J-28485
Rear Disc Models J-28497
Piston Installation Tool
Diesel Models J-25083
All Others J-24551
Special Deep Socket J-24554
Tube Seat Installer J-6217
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