.

INDEX

General Information
Installing Power Brake Unit
Power Brake Vacuum Hose
Removing Power Brake Unit
Service Procedures
Vacuum Hose Chart

GENERAL INFORMATION  (back to CONTENTS)

Different emission systems and engine combinations require different vacuum hose routings.

All cars use a charcoal filter. Refer to chart and drawing for correct application.

Make sure hoses are matched exactly for length with the one being replaced.

Never use a substitute hose for the two inch hose connecting the charcoal filter to the carburetor nipple as the composition of the two inch hose is a special gasoline resistant material.

The power brake unit mounts on the engine side of the dash panel and is externally connected to the brake system by a pedal link to the brake pedal by a vacuum line to a nipple on the base of the carburetor (through a check valve) and to the master cylinder bolted to the front.

SERVICE PROCEDURES

POWER BRAKE VACUUM HOSE  (back to CONTENTS)

For hose replacement refer to chart for application by engine for proper hose length.  Also see figures 1 and 2.

VACUUM HOSE CHART  (back to CONTENTS)

Car Line	Engine	Booster Hose Length	Carburetor Hose Length
B,F,G	318 2BBL	12.0 in.	4.0 in. HYP.
B,F,G	318 4BBL	14.0 in.	2.0 in. HYP.

REMOVING POWER BRAKE UNIT  (back to CONTENTS)

(1) Remove nuts attaching master cylinder to power brake unit. Carefully slide master cylinder off mounting studs and allow to rest against fender shield (Fig. 3).
(2) Disconnect vacuum hoses from power brake.
(3) From under instrument panel, position a small screwdriver between the center tang on the retainer clip and the pin in the brake pedal (Fig. 4). Rotate screwdriver enough to allow retainer clip center tang to pass over end of brake pedal pin and pull retainer clip from pin. Discard retainer clip.
(4) Remove lower pivot retaining bolt and nut. (Fig. 4).
(5) Remove four power brake attaching nuts.
(6) Rotate linkage as necessary and remove power brake unit from vehicle.
(7) Remove pivot bushings and sleeve for reuse.

INSTALLING POWER BRAKE UNIT  (back to CONTENTS)

(1) Rotate linkage as necessary and position power brake booster onto dash panel. Install and tighten four mounting nuts to 200-250 in. lbs. (23-28 N•m).
(2) Carefully position master cylinder on power brake unit. Install and tighten mounting nuts to 200 in. lbs. (23 N•m).
(3) Connect vacuum hoses.
(4) Using lubriplate, or equivalent, coat the bearing surface of pedal pin. Connect linkage to pedal pin and install new retainer clip.
(5) Coat pivot bushings and sleeve with lubriplate, or equivalent. Install into linkage. Position linkage and install lower pivot bolt. Tighten to 18 ft. lbs. (24 N•m).
(6) Check stoplight operation and readjust if necessary.

CAUTION: Do not attempt to disassemble power brake unit as this booster is serviced as a complete assembly only.