Power Brake Units - BENDIX Tandem Diaphragm: Overhaul: Reassembly
- It rear bearing and seal were removed, install new parts, using suitable driver (J-22677). Install reaction disc to front plate hub, with small tip toward hole. Mount front plate on hex stock or other suitable tool (J-22839). Position diaphragm on front plate, with long fold facing down). Place suitable seal protector tool (J-22733) over hub threads, apply light coat of suitable lubricant to hub and seal in center plate, then guide center plate, seal first, onto hub. Lightly lube air valve plunger bearing surfaces (avoid lubing inner rubber grommet). Install vacuum "O" ring seal on shoulder of front plate hub, and insert valve plunger and return spring in base of front plate hub. Screw rear plate onto front plate hub, by hand (torque to 150 in. lbs.). Check travel of valve plunger with finger.
- Assemble rear diaphragm to rear plate (place diaphragm lip in plate groove). Install rear diaphragm retainer. Apply talcum powder to inner wall of rear housing, and suitable lubricant to scallop cutouts and rear housing seal. Assemble diaphragm and plate assembly into rear housing (align center plate bosses between rear housing lances). Using screwdriver, work outer rim of diaphragm into rear housing. On Imperial, install small end of diaphragm return spring over center plate hub nut. On Lincoln and Thunderbird, install small end of diaphragm return spring over front shell hub. Attach rear housing to suitable tool (as used during separation - J-23456). Insert diaphragm return spring. Place front housing over rear housing (note location of scribe marks). Apply downward pressure until diaphragm edge is fully compressed, then rotate bar clockwise to lock housings. Remove from tool and bend four deep tabs back to original locking position.
- Dip poppet valve in clean alcohol and install in rear plate hub (small end first). Dip poppet retainer in alcohol and install it in poppet. Assemble retainer, filters, silencers, and return spring on valve rod. Dip valve plunger grommet in alcohol and install valve rod into plunger. Tap end of valve rod with plastic hammer to lock ball in grommet. Press filters and silencers into hub and install outer retainer. Assemble silencer in dust boot, wet boot with alcohol, and assemble on rod and over rear flange. Install check valve, if removed. Apply lubricant to piston end of hydraulic push rod and insert in cavity in front plate. Twist rod to eliminate air bubbles at reaction disc. Assemble seal over push rod and press into front housing recess.
Courtesy of CHRYSLER GROUP, LLC