Brake Booster - BENDIX Single Diaphragm: Reassembly
- Install vacuum check valve grommet (beveled edge on inside) after dipping part in denatured alcohol.
- Install front housing on a holding fixture (J-22805), and clamp fixture in a vise.
- Install new rear housing seal using seal installer tool (J-22677), tool bottoms on housing when seal is in place.
- Assemble diaphragm plate assembly as follows: Lubricate outer diameter of diaphragm plate, extension, valve, plunger bearing surfaces and edge of poppet valve. Install valve and rod into diaphragm plate extension. Depress pushrod and install lock. Install rolling diaphragm in diaphragm plate groove. Lubricate and install reaction disc. Use master cylinder push rod to seat disc in diaphragm bore.NOTE: If disc is not fully seated, push rod height will be incorrect.
- Lubricate inside of bearing seal and diaphragm contact surface of rear shell. Install diaphragm plate assembly in rear housing. Install air filter and retainer into diaphragm plate extension.
- Complete assembly as follows: Place spanner wrench on rear housing. Press wrench down and turn rear housing counterclockwise to lock housings together. Make sure scribe marks align. Bend tabs back into place so housings will not come apart. If any tabs are broken, replace housing.
- Install air silencers, push rod boot and retainer. On clevis type push rods, install lock nut and clevis. Lubricate piston rod (except rounded end). Install rod into center bore until seated against reaction disc. Install front housing seal in same manner as rear seal. Install master cylinder and bleed system if necessary.