Contents: Removal ⬇ Installation ⬇
Fig. 9.4. Assembling the brake pedal rod and vacuum booster/master cylinder
1. Booster push rod and threaded adjuster; 2. Assembly of the vacuum booster unit; 3. Rubber cover; 4. Compaction; 5. Washer; 6. O-ring seal; 7. Hose coupling; 8. Hose; 9. Non-return check valve; 10. Washer; 11. Spring washer; 12. Nut; 13. Spring washer; 14. Nut; 15. Left traction bracket; 16. Right traction bracket; 17. Dust cover; 18. Retaining ring; 19. Hinge bushing; 20. Traction crossbar; 21. Locking bracket; 22. Pedal drive rod; 23. Rubber cover; 24. Washer; 25. Bracket; 26. Compaction (models produced since 1992).
Removal
1. Remove the vacuum booster unit. If you want to make the procedure easier (see Chapter 5). If the booster will remain in the tie rod mounting bracket, remove the locking clip that secures the booster push rod eye to the tie rod. Have an assistant depress the brake pedal so that access can be gained through the slot in the side of the mounting bracket.
2. Remove the dust cover and snap ring from the left end of the pedal link crossbar.
3. Remove the nuts securing the left tie rod bracket to the bulkhead, then remove the bracket from the end of the rod; pay attention to the hinge bushing, washer and (on models produced since 1992.) seal (see photo). If the vacuum booster unit is still attached to the bracket, very carefully (see Chapter 5) unhook the booster push rod from the pedal rod cross rod, being careful not to bend or damage the metal brake pipes.
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4. Have an assistant depress the brake pedal so that you can access the slot in the side of the right bracket and remove the locking clip securing the drive link eye to the pedal link crossmember pin.
5. Remove the dust cover and snap ring from the right end of the pedal link crossbar (see photo).
6. Remove the cross rod from the right bracket; also take the ball joint bushing and washer (see photo).
7. If the right tie rod bracket needs to be removed, note that the nuts securing it to the bulkhead also secure the pedal bracket inside the vehicle. Either secure the pedal bracket in its operating position to avoid disturbing the pedals, or disconnect the throttle and clutch cables (see Sections 4 and 6 respectively) and the wires of the brake light switch (see Chapter 27), so that the assembly can be removed.
8. Clean all components and inspect the working surfaces and hinge parts for damage and signs of wear. Replace any worn or damaged components - hinge bushings are sold separately (see photo).
Installation
9. Install in the reverse order of removal, paying attention to the following:
- a) Apply a thin coat of general purpose grease to all hinge parts and working surfaces.
- b) Tighten all nuts and bolts to the specified tightening torque Specifications (where given).
- c) Check and adjust, if necessary, the brake pedal height (see Chapter 3).