Hydraulic Assembly

Fig. 6 - Removing or Installing Hydraulic Assembly:

REMOVAL

De-pressurize the hydraulic accumulator by pumping the brake pedal a minimum of 40 times, as described in this section.

WARNING: FAILURE TO DE-PRESSURIZE 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 battery and all electrical connectors from the hydraulic assembly.

(3) Remove as much fluid as possible from the reservoir on the hydraulic assembly.

(4) Remove pump high pressure hose fitting from hydraulic assembly.

(5) Disconnect pump return hose from filter nipple. Cap spigot on filter.

(6) Disconnect all brake tubes from hydraulic assembly (Fig. 6).
(7) 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 pedal pin. Discard the retainer clip (Fig. 6).

(8) Remove four hydraulic assembly mounting nuts (Fig. 6).

(9) Remove hydraulic assembly.

INSTALLATION

(1) Position hydraulic assembly on vehicle.

(2) Install and tighten mounting nuts to 28 N-m (250 in.lbs.) torque.

(3) Using lubriplate or equivalent, coat the bearing surface of pedal pin.

(4) Connect push rod to pedal pin and install a new retainer clip. HYDRAULIC ASSEMBLY PUSH ROD MUST BE ASSEMBLED TO BRAKE PEDAL PIN AS SHOWN IN (FIG.6).

(5) Install brake tubes. If proportioning valves were removed from the hydraulic assembly, install and tighten to 40 N-m (30 ft.lbs.) torque.
(6) Install return hose to nipple on filter.

(7) Install pressure hose to hydraulic assembly. Tighten the hose, to hydraulic assembly fitting to 18 N-m (10 ft.lbs.)


(8) Fill reservoir to top of screen.

(9) Connect battery and all electrical connectors to the hydraulic assembly.

(10) Bleed the entire brake system, see Bleeding Brake System in this section.

(11) Install fresh air intake duct.