Early Production

REMOVAL
Depressurize hydraulic accumulator as outlined under MAINTENANCE PROCEDURES.
WARNING: Failure to depressurize hydraulic accumulator, prior to performing this operation, may result in personal injury and/or damage to painted surfaces.
1. Remove fresh air intake duct clamps at air cleaner and throttle body. Remove duct from vehicle.
2. Disconnect electrical connectors from the hydraulic assembly, then remove as much fluid as possible from reservoir on hydraulic assembly.
3. Remove pressure hose banjo bolt from hydraulic assembly taking care not to drop the two washers.
4. Disconnect return hose from reservoir nipple and cap spigot on reservoir.

Fig. 50 - Brake Tube and Hose Routing at Hydraulic Assembly:

5. Disconnect all brake tubes from hydraulic assembly.

Fig. 51 - Removing or Installing Hydraulic Assembly:

6. From under the instrument panel, position a small screwdriver between the center tang on the retainer clip and the pin in the brake pedal. Rotate the screwdriver enough to allow the retainer clip center tang to pass over the end of the brake peal pin. Discard the retainer clip.
7. Remove driver's side sound insulator panel, then remove four hydraulic assembly mounting nuts and hydraulic assembly.

INSTALLATION
1. Install hydraulic assembly on vehicle and torque mounting nuts to 28 N-m (250 lb-in).
2. Coat pedal pin bearing surface with "Lubriplate", or equivalent.
3. Connect push rod to pedal pin and install a new retainer clip.
4. Connect brake tubes to the proper proportioning valve. The longer tube goes on inboard proportioning valve. If proportioning valves were removed from the hydraulic assembly, install and tighten to 27 N-m (20 lb-ft).
5. Install return hose to nipple on reservoir.
6. Install pressure hose to hydraulic assembly, be sure two washers are positioned correctly. Tighten the "banjo" bolt to 18 N-m (160 lb-in).
7. Fill reservoir to top of screen.
8. Connect all electrical connectors to the hydraulic assembly.
9. Bleed brake system, see MAINTENANCE PROCEDURES.
10. Install fresh air intake duct.