DEMO - 1965 Ford Truck Shop Manual - ForelPublishing.com

PART 2-4 - VACUUM BOOSTERS 2-53
except where indicated in the procedure
steps and illustrations.
DISASSEMBLY
1. Loosen the control tube hose
clamps and slide the hose off the end
of the tube (Figs. 30 and 31).
2. Remove the air inlet tube snap
ring and remove the air inlet tube,
seal, and spring from the control
valve body.
3. Remove the five control valve
body mounting screws and remove
the body, return spring, diaphragm,
and gasket from the end plate. The
poppet valve cannot be removed
from the valve body.
4. Mount the end cap in a vise,
loosen the hydraulic cylinder lock
nut, and unscrew the end plate and
booster body assembly from the hydraulic
cylinder.
5. Unscrew the hydraulic cylinder
from the end cap, then remove the
lock nut and seal from the cylinder.
Remove the bleeder screw and copper
gasket from the end cap then remove
the end cap from the vise (Figs.
30 and 31).
On a -9V£-inch booster, remove the
check valve snap ring, washer, spring,
and check valve (Fig. 31). A truck
with a 9 V2-inch booster has a check
valve mounted in the end cap. Therefore,
a check valve is not used in the
master cylinder on these trucks.
6. Scribe a line across the booster
body and end plate so that these
parts can be reassembled in their original
position. Remove the four hook
bolts, and slide the booster body
from the vacuum piston assembly.
7. Compress the vacuum piston
return spring by pressing down on
the end plate and using hook-type
clamps similar to those in Fig. 32.
Hold the spring compressed.
8. Remove the hydraulic piston
from the push rod by sliding the retainer
spring (on the hydraulic piston)
back, and removing the retainer
pin.
9. Remove the hook clamps and
separate the vacuum piston and push
rod assembly, and the return spring
from the end plate.
10. Clamp one of the bolt flanges
of the end plate in a vise. Unscrew
the control valve cylinder from the
end plate, then remove the rubber
gasket from the cylinder. Remove the
snap ring retainer and stop washer,
then press the control valve piston
assembly from the cylinder (Figs. 30
and 31). The piston should come out
of the front end of the cylinder to
avoid damage to the cups.
11. On a 6%-inch booster, remove
the small retainer, then remove
the piston cups and spacer from the
control valve piston (Fig. 30).
On a 9Vi-inch booster, remove the
cups from the piston (Fig. 31).
12. Remove the hydraulic cylinder
end seal from the end plate (Figs.
30 and 31). Remove the snap ring,
then remove the push rod seal cup
parts from the end plate (6% -inchretainer
washer, spring spacer, seal
retainer, seal cup and stop washer as
shown in Fig. 30). (9V£ -inch—washer,
spring, retainer washer, seal cup, and
stop washer as shown in Fig. 32.)
13. Remove the end plate from
the vise and place it on two wooden
blocks with the hydraulic cylinder
side up. Drive the push rod leather
seal assembly out of the end plate,
using a flat end rod or drift.
14. On a 6 3 A -inch booster, clamp
the vacuum piston and push rod assembly
in a vise at the hexagonal nut.
Remove the vacuum piston retaining
CONTROL
TUBE
DIAPHRAGM
PISTON
CUPS
AIR INLET
TUBE
PUSH-ROD
LEATHER
SEAL
PUSH-ROD
HYDRAULIC
SEAL PARTS
END PLATE
CYLINDER
END SEAL
SNAP RING
HECK VALVE
FIG. 31-End Play Disassembled-^-Inch Booster
HI 020- A