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Power Brake Unit: Reassembly

  1. On Civic, seat inner valve in groove of push rod (note valve direction) and lubricate with silicone grease. Install outer valve on holder.
  2. Install push rod through valve holder and seat metal end of outer valve in groove of inner valve. Install inner and outer valve springs, spring seat, and felt silencer into valve holder and secure with circlip.
  3. On Accord & Prelude, install poppet valve on valve holder. Install valve holder, inner valve spring, outer valve spring and spring seat on push rod. Install silencer with circlip.
  4. Align diaphragm tabs with slots in piston and install. Apply silicone grease to inner and outer piston tube surfaces. Press valve holder assembly into booster piston tube and install snap ring.
  5. On all models, slip foam filter over end of push rod. Thread adjuster and lock nut onto shaft but do not tighten.
  6. On Civic, slip new diaphragm over piston and press retainer ring into place. Apply silicone grease to inner and outer surfaces of piston tube. Press valve holder in power unit piston tube.
  7. On all models, apply silicone grease to piston seal. Install piston seal with lip of seal facing inward. Install bushing in rear housing and drive retainer in until seal bottoms.
  8. On Civic, install diaphragm/piston assembly into rear housing. Install snap ring in groove of push rod.
  9. Install reaction plates, reaction ring and reaction cover.
    NOTE: Reaction plates must be installed with rounded portion facing reaction ring. Install reaction ring with rubber end facing plates. Apply silicone grease to plates.
  10. Apply silicone grease to sealing lip and in groove of new rod seal. Install rod seal in front housing with flat side of seal inward.
  11. On Accord & Prelude, install through bolts, using "O" rings and snap rings. Attach piston to rear housing, aligning tab of piston with slot in rear housing. Install boots on through bolts.
  12. Apply silicone grease to bore of piston. Install push rod seat, reaction disc, output rod and retainer. Install booster spring, compress and install spring retainer and snap rings.
  13. To complete reassembly, reverse removal procedure. On Civic, check that push rod end comes through front housing bore when assembling.
  14. Before installing master cylinder to power brake unit, check master cylinder-to-push rod clearance and adjust as necessary.
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