Assembly
POWERMASTER UNIT ASSEMBLY
CAUTION: Do not immerse pressure switch (1) or E-H pump (8) in alcohol. Exterior surfaces may be wiped with a clean cloth lightly moistened with denatured alcohol if necessary.
Exploded View Of Powermaster Assembly:
Cleaning and Inspection:
- Clean all parts except pressure switch (1) and E-H pump (8) in clean, denatured alcohol.
- Dry with filtered compressed air.
- Inspect all metal parts for cracks, distortion or other evidence of structural damage.
- Inspect primary sealing surfaces on power piston (25) for scoring, deep scratches or other damage that would cause leakage. if noted replace power piston assembly.
- Inspect power piston and master cylinder bores in Powermaster body for scoring or corrosion. If noted, replace power brake assembly. No abrasives shall be used.
NOTE:
^ Use clean, fresh brake fluid to lubricate parts prior to assembly.
^ Lubricate new rubber O-rings, grommets and seals with clean brake fluid just prior to assembly.
^ Lubricate master cylinder and power piston bores in Powermaster body before installing parts.
Assembly
1. Install Powermaster body (39) in vise.
2. Install new spring (38) and poppet (37) in Powermaster body (39).
3. Install new valve seat and seal (36) in Powermaster body (39).
4. Bottom out valve seat and seal (36) by threading nut of tube and nut assembly (12) into Powermaster body port.
5. Remove Powermaster body (39) from vise.
6. Install grommets (34 and 35) into Powermaster body (39).
CAUTION: Make sure grommets are properly seated.
Figure 9 Installing Reservoir:
7. Install reservoir (33) to Powermaster body (39).
8. Install spring (31) in Powermaster body (39).
9. Install secondary seal (27), primary seal (29) and spring retainer (28) on secondary piston (30).
10. Install secondary piston assembly (27 thru 30) in Powermaster body (39).
11. Install primary piston assembly (26) in Powermaster body (39).
12. Install reaction piston (23) and new reaction disc (23) in reaction body group (22).
13. Install two O-rings (21) on power piston assembly (25).
14. Install reaction body group (22) in power piston assembly (25).
15. Install power piston assembly (25) in Powermaster body (42).
16. Install one O-ring (21) on piston guide (19); O-ring (20) in piston guide.
17. Install piston guide (19) in Powermaster body (39), over power piston (23).
18. Install retainer (18) while depressing piston guide (19) and power piston (25).
19. Install boot, pushrod, socket group (17), socket into end of power piston assembly (25) and retained with retainer (16).
20. Assemble external components:
Figure 5 Sump Hose, Tube Nut & Assembly, and Motor and Pump Brackets:
a. Install brackets (14 and 15) with bolts (13) and torque to 20-34 Nm (15-25 lb. ft.).
b. Install sump hose (10), clamps (9), tube and nut assembly (12). Torque tube and nut assembly to 13-20 Nm (10-15 lb. ft.).
Figure 4 E-H Pump And Pressure Hose:
c. Install E-H pump (8), washers (6) and attaching nuts (5) and torque to 2.6-4.0 Nm (23-35 lb. in.).
d. Install pressure hose assembly (11).
- First connect end of hose assembly (11) to E-H pump (8) and torque to 13-20 Nm (10-15 lb. ft.).
- Connect other end of pressure hose assembly (11) to tube and nut assembly (12) and torque to 13-20 Nm (10-15 lb. ft.).
e. Install end of sump hose (10) and hose clamp (9) to E-H pump (8).
Figure 3 Accumulator:
f. Install O-ring on accumulator (3) then torque accumulator (4) to 20-27 Nm (15-20 lb. ft.)
Figure 2 Pressure Switch:
g. Install O-ring (2) on pressure switch (1) and torque pressure switch to 20-27 Nm (15-20 lb. ft.)
21. Install reservoir cover and diaphragm (32) on reservoir (33).
22. Install Powermaster assembly in vehicle.