DEMO - 1965 Ford Truck Shop Manual - ForelPublishing.com

PART 2-4 - VACUUM BOOSTERS 2-59
PUSH
ROD
SEAl>
PISTON
ROD NUT
PISTON PLATE
HI 062-A
FIG. 48—Rear Vacuum Piston,
Return Spring, and Outer Plate
Assembly
nut until it is flush with the face of
the piston rod, and stake the nut
securely at opposite points.
19. Hold the piston rod nut in a
vise or with a wrench, and tighten
the inner nut securely against the
piston. Care must be exercised when
tightening the inner nut to prevent
the retainer plate from shifting.
20. Remove the assembly ring,
then remove the rod holding the return
spring compressed.
21. Hold the end cap in a vise,
and assemble the parts as shown in
Fig. 39. The small end of the spring
must be placed inside the check
valve clips.
22. Install a new copper gasket in
the end cap. The hydraulic cylinder
must be assembled with the milled
flats next to the end cap. Tighten the
hydraulic cylinder solidly in the end
cap, and thread the lock nut on the
hydraulic cylinder up to the limit of
the threads.
23. Install the lock nut seal (if
used) in the groove of the cylinder
tube. Install the bleeder screw in
the cap.
24. Press the leather seal into the
hydraulic cylinder bore of the front
end of the plate from the inner side
of the plate with the lip of the seal
toward the outer end of the plate
(Fig. 46).
25. Install the push rod seal and
related parts in the order shown in
Fig. 46. The chamfered side of the
washer is down, the lip of the push
rod seal is up, the flat side of the
flange washer is next to the seal. Install
the retaining washer.
26. Install the snap ring in the
inner groove of the end plate.
27. Place the rear end plate on
the holding fixture (Fig. 47), and install
the stop washer with the flat
side in the valve fitting. Install the
retainer.
28. Dip the hydraulic piston cups
in brake fluid, and assemble them on
the hydraulic piston with the lips of
the cups positioned away from each
other.
29. Insert the piston into the
valve fitting with the open end of the
piston toward the stop washer.
30. Install a new gasket on the
valve fitting (copper gasket on the
fitting without the groove, and a
rubber seal gasket on the fitting with
the groove).
31. Install the valve fitting in
the end plate. Tighten the fitting
equipped with a rubber gasket firmly.
Torque the fitting equipped with a
copper gasket to 325-330 ft-lbs.
32. Assemble the vacuum control
valve parts in the control body in
sequence shown in Fig. 38. Install a
new lead washer.
33. Install the tee fitting and tubes
on the center plate. The small diameter
pipe on the vacuum tee should
be toward the front end plate.
34. Dip the front piston leather
packing and wicking in vacuum cylinder
oil, and allow the excess oil to
drain off.
35. Position a new gasket on the
front edge of the center plate. Install
the front cylinder to the center plate
(Fig. 49). Coat the interior of the
cylinder with vacuum oil. Carefully
guide the push rod through the seal
in the front end plate. At the same
time, align the vacuum tube in the
end plate with the vacuum tube on
the center plate.
CENTER
PLATE
(FRONT)
PISTON
(FRONT)
CYLINDER
FIG. 49—Front Cylinder and
End Plate Installation
(FRONT)
END
PLATE
36. Position a new gasket on the
front end plate and place on the
front cylinder.
37. Slide the hose in place to connect
the 2 vacuum tubes.
38. Position a new gasket on the
other edge of the center plate (Fig.
40). Coat the interior of the rear
cylinder with vacuum cylinder oil,
then tip the front cylinder and end
plate assembly at a 45-degree angle
to prevent damage to the rear piston
leather packing. Carefully push the
rear cylinder over the rear piston
and onto the center plate.
39. Place a new gasket on the
rear end plate, then install the end
plate on the rear cylinder, aligning
the end plate vacuum tube and center
plate vacuum tube.
40. Install the cylinder studs and
tighten the nuts evenly.
41. Position the vacuum hoses on
the tubes, and tighten the hose
clamps firmly.
42. Connect the hydraulic by-pass
tube to the front and rear end plates.
Install the by-pass tube retaining clip
and screw to the center plate.
43. To assemble the hydraulic piston
parts, place the large end of the
spring in the retainer cup, and install
the check ball in the piston body
behind the spring.
44. Dip a new piston cup in brake
fluid, and install it on the piston with
the lip of the cup toward the check
ball.
45. Install the booster assembly in
an arbor press, and insert a brass
drift through the atmospheric port in
the rear end plate. Press the hydraulic
cylinder piston until the piston
rod is exposed at the front end plate.
Assemble the hydraulic piston on the
push rod and install the retaining
pin. Remove the assembly from the
press. Install the seal on the hydraulic
cylinder.
46. Carefully guide the hydraulic
cylinder over the piston cup, and
thread the cylinder into the end
plate. Align the bleeder screw in the
end cap with the bleeder screw in
control valve. Adjust the hydraulic
cylinder to a minimum of 8 1 %6
inches (Fig. 50). Tighten the lock
nut.
47. Install 5 guide pins, made
from 8-32 x 2 V^-inch machine