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Power Brake Unit: Disassembly

  1. Remove master cylinder and check valve from power unit. Place power unit in a vise with push rod up. Scribe alignment marks on front and rear shells to assure reassembly in original position. Remove clevis, lock nut, and dust boot from rear shell. See Figure .
    CAUTION: Separate front and rear shells carefully. Spring tension may cause rear shell to release quickly.
  2. Attach a bar and plate tool to rear shell mounting studs. Press down on tool while rotating it counterclockwise to unlock rear shell. Lift rear shell assembly from power unit, remove air silencer retainer, and separate diaphragm from power piston assembly. Remove valve rod with plunger assembly from rear shell.
    NOTE: Service valve rod plungers as an assembly.
  3. On all models, remove lock plate and press valve rod in to remove valve retainer key.
  4. Remove valve rod and plunger assembly. Remove air silencer and filter. Remove retainer and bearing. Never remove rear seal from rear shell unless seal is defective and a new one is available. Remove push rod, front seal, and support plate.
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