DEMO - 1965 Ford Truck Shop Manual - ForelPublishing.com

2-58 GROUP 2 - BRAKES
VALVE
PISTON
ROD SEAL
H1059-A
FIG. 45-Fast Application Valve
and Piston Rod Seals
flat side down. Remove the O-ring
seal, snap ring and retainer washer,
flange washer, push rod seal, and
stop washer from the end plate (Fig
46).
(FRONT) END PLATE
FLANGE
WASHER
BUSHING
FIG. 46-Hydraulic Cylinder
Push Rod Seals
LEATHER
SEAL
HI 060-A
23. Drive the push rod leather
seal out of the end plate.
24. Remove the retainer and stop
washer from the valve fitting and remove
the fitting. Push the hydraulic
piston out of the valve fitting, and
remove the gasket from the valve
fitting (Fig. 47).
25. Remove the cups from the hydraulic
piston.
ASSEMBLY
1. Assemble the rear vacuum piston
by installing the nut on the rear
vacuum piston end of the piston rod
with the flat side of the nut upward
(Fig. 42).
2. Position the larger diameter piston
plate on the piston rod with the
chamfered side of the hole at the
top. Guide the rubber seal ring over
the threads of the piston rod.
3. Place an assembly ring on a
flat surface and install the leather
STOP
WASHER
RETAINER
H1061-A
FIG. 47-Hydraulic Control Valve
Piston and Fitting
packing, with the lip side upward.
Then position the smaller diameter
piston plate, with chamfered side of
the hole downward, in the ring.
4. Cut a new piece of wick to the
required length, then place it against
the inner face of the leather packing
lip. Assemble the wick retainer, with
the gripper points upward, against
the wick, and hook the notched end
of the retainer under the clip near
the opposite end of the ring.
5. Position the cut-out of the retainer
plate over the loop of the
wick retainer.
6. Hold the piston parts in the assembly
ring, assemble them on the
end of the piston rod, then install
the nut on top of the piston assembly.
Tighten the nut until it is flush
with the end of the piston rod. Stake
the nut securely at two places.
Clamp the staked nut firmly in a
vise, and tighten the nut on the opposite
side of the piston plate solidly
against the piston plate.
7. Press the fast application valve
shaft and rod seals (Fig. 45), into the
center plate. The piston valve shaft
seal must be flush with the bottom
of the hole. The piston rod seal
should rest against the shoulder of
the center plate.
8. Position the center plate as
shown in Fig. 44, then place the return
spring on top of the seal with
the small end at the top. Install the
bullet-nosed tool on the threaded
end of the valve shaft, and insert the
valve shaft through the seal. Position
the gasket on the center plate.
9. Place the valve seat plate, with
the seat side downward, on the gasket,
and install the screws and lockwashers.
10. Turn the center plate over.
Place the lower diaphragm plate,
with the rounded edge up, on the
valve shaft, then place the diaphragm
gasket on top of the plate
(Fig. 43). Position the diaphragm on
top of the gasket so the screw holes
and the by-pass hole index with the
identical holes in the center plate.
Install the other diaphragm plate
with the rounded edge facing the
diaphragm.
11. Install the nut on the valve
shaft. Use a screwdriver to prevent
the shaft from turning, and tighten
the nut. Stake the nut securely at 2
opposite points.
12. Position the gasket and valve
cover on the center plate, then install
the screws and lock washers.
13. Place the return spring over
the piston rod with the small end of
the spring at the bottom (Fig. 41).
14. Carefully guide the piston rod
through the seal in the center plate,
with the piston stop flanges of the
center plate facing upward. Press the
center plate down against the spring,
and insert a rod in the piston rod.
15. Assemble the large end of the
push rod in the end of the piston
rod, and install the pin.
16. Thread the piston rod nut on
the piston rod, with the flat side of
the nut upward, to the limit of the
threads.
17. If the front piston was disassembled
to replace the leather piston
packing, the cotton wicking, or
other parts, assemble the piston parts
in the assembly ring in the same
order as the rear piston (Fig. 42).
Hold the parts in the ring and turn
the assembly ring over. Remove the
larger diameter piston plate and seal.
With the assembly ring still in place,
guide the remaining piston parts
over the end of the push rod and
against the piston rod nut (Fig. 48).
Carefully install the seal over the
threads of the piston rod. Place the
larger diameter piston plate on the
piston rod, with the chamfered side
of the hole toward the seal.
18. Install the piston rod nut,
with the flat side downward, on the
end of the piston rod. Tighten the