06 1963 CH-Brakes

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6-9

SECTION 6

BRAKES
CONTENTS OF THIS SECTION
Page
Standard Brakes 6- 1
Metallic Brakes 6- 8
Power Brakes-Bendix
Power Brakes-Moraine 6-14
Special Tools 6-20
Specifications See Section 16

STANDARD BRAKES
INDEX
Page Page
General Description 6-1 Service Operations 6-3
Self-Adjusting Features.. 6-1 Brake Drums, Shoes and Linings 6-3
Main Cylinder 6-2 Adjustments 6-5
Parking Brake 6-2 Clutch and Brake Pedals 6-6
Hydraulic Brake Hose 6-2

GENERAL DESCRIPTION
Service of the 1963 passenger car hydraulic brakes
will essentially be accomplished as outlined in the
1961 Passenger Car Shop Manual. Various design
changes have been incorporated in the 1963 models;
however, these changes will not effect over-all service
procedures except as described below or outlined
under "Service Operations" in this section.

Self-Adjusting Feature
Brake shoe adjustment takes place when brakes are
applied with a firm pedal effort while vehicle is back
ing up. Applying the brakes moves an actuator which
turns the star wheel and lengthens the adjusting screw
assembly fig. 1. This action adjusts the shoes until
clearance between the lining and drum is within
proper limits.
Should low pedal heights be encountered, it is rec
ommended that numerous forward and reverse stops
be performed with a firm pedal effort until a satisfac
tory brake pedal height results.
NOTE: Frequent usage of an automatic trans
mission forward range to halt reverse vehicle
motion may prevent the automatic adjusters
from functioning, thereby inducing low pedal Fig. 1 -Self-Adjusting Brakes
heights.

PASSENGER CAR SHOP MANUAL SUPPLEMENT


BRAKES-STANDARD 6-2

Brake Drum ing. The main cylinder bleeding adapter fig. 4 is


designed to allow filling of the reservoir to the proper
A lanced "knock out" area is provided in the web level ¼" from the reservoir rim during the bleeding
of the brake drum for servicing purposes in the event operation.
retracting of the brake shoes is required in order to
remove the drum fig. 2.

MAIN CYLINDER
The brake main cylinder fig. 3 is functionally the
same as past models, but due to design of the reser
voir, a special adapter is required for pressure bleed-

Fig. 4-Brake Pressure Bleeding Adapter Installed

PARKING BRAKE
Release Handle Replacement
If replacement of the release handle is necessary,
all of the existing handle and any material used to
secure it should be cleaned from the release rod.
After the rod has been effectively cleaned, proceed
as follows:
1. Heat the handle of the release rod to approxi
mately 115 degrees.
Fig. 2-Brake Drum Access Hole 2. Slowly insert the new handle on the release rod-
push gently and slowly on handle to allow heat
from the rod to be absorbed by handle and to
align properly on the rod. When the rod has
cooled, the plastic handle will contract and grip
the rod securely.
HYDRAULIC BRAKE HOSE
Replacement
When replacing hydraulic brake hose, follow pro
cedure outlined in 1961 Passenger Car Shop Manual
and the following.
Inspect hose installation by removing weight com
pletely from wheel and turn wheels from lock to lock,
while observing hose position. Be sure that hose does
not touch other parts during suspension or wheel
travel. If contact occurs, remove hose retainer and
rotate female hose end in support bracket in appropri
ate direction, replace retainer, and reinspect.
CAUTION: Under no circumstances should
brake hoses be tightened at the wheel cylin
Fig. 3-Main Cylinder der with the female hose end in the support
1. Thumb Screw 5. Gasket 9. Spring bracket. Always remove hose from support
2. Vent Cover 6. Body 10. Primary Cup bracket, tighten hose at wheel cylinder, then
3. Flat Washer 7. Valve Seat 11. Secondary Cup and Piston
4. Reservoir Cover 8. Valve Assembly 12. Lock Ring install hose in support bracket.

PASSENGER CAR SHOP MANUAL SUPPLEMENT


BRAKES-STANDARD 6-3

SERVICE OPERATIONS
The service operations which differ from those out 4. Unhook brake shoe pull back springs from anchor
lined in the 1961 Passenger Car Shop Manual are de pin and link end, using Tool J-8049 fig. 5.
scribed below. 5. Remove the actuator return spring.
6. Disengage the link end from the anchor pin and
BRAKE DRUMS, SHOES AND LININGS then from the secondary shoe.
NOTE: If brake drums are worn severely, it 7. Remove hold-down pins and springs fig. 6.
may be necessary to retract the adjusting
screw. To gain access to the adjusting screw
star wheel, knock out the lanced area in the
web of the brake drum using a chisel or simi
lar tool.

CAUTION: After knocking out the metal, be


sure to remove it from the inside of the drum
and clean all metal from the brake corn part
ment. A new hole cover must be installed when
drum is reinstalled.

Removal
1. Raise the vehicle and place on stand jacks.
2. Loosen check nuts at forward end of parking
brake cable sufficiently to remove all tension from
brake cable.
3. Remove brake drums.
NOTE: Since boots are recessed in grooves on
wheel cylinders to prevent pistons from leaving
cylinders, it is not necessary to install wheel
cylinder clamps when brake shoes are re
moved; however, brake pedal must not be de
pressed while drums are removed. Fig. 6-Removing Hold-Down Springs and Pins

8. Remove the actuator assembly.


NOTE: The actuator, pivot and override spring
are an assembly. It is not recommended that
they be disassembled for service purpose, un
less they are broken. It is much easier to as
semble and disassemble the brakes by leaving
them intact.
9. Separate the brake shoes by removing adjusting
screw and sprmg fig,. 7.
10. Remove parking brake lever from secondary
brake shoe rear only.
11. Clean dirt out of brake drum using care to avoid
getting dirt into front wheel bearings. Inspect
drums for roughness, scoring or out-of-round. Re
place or recondition drums as necessary.
12. Inspect wheel bearings and oil seal and replace
any necessary parts.
13. Carefully pull lower edges of wheel cylinder boots
away from cylinders and note whether interior is
wet with brake fluid. Excessive fluid at this point
indicates leakage past piston cups requiring over
Fig. 5-Unhook Pull Back Spring haul of wheel cylinder.

PASSENGER CAR SHOP MANUAL SUPPLEMENT


BRAKES-STANDARD 6-4

Fig. 7-Spreading Brake Shoes for Removal


Fig. 8-Checking Operation of the Actuating Lever

NOTE: A slight amount of fluid is nearly always


present and acts as lubricant for the piston.

14. If working at rear wheels, inspect backing plate


for oil leakage past axle shaft oil seals. Install new
seals if necessary.
15. Check all brake flange plate attaching bolts to
make sure they are tight. Clean all rust and dirt
from shoe contact faces on flange plate, using fine
emery cloth.

Installation

CAUTION: Make certain to install recommended


shoe and lining assemblies. Otherwise, serious
fade or permanent failure may occur.

1. Inspect new linings and make certain there are no


nicks or burrs or bonding material on shoe edge
where contact is made with brake flange plate or
on any of the contact surfaces.
NOTE: Keep hands clean while handling brake
shoes. Do not permit oil or grease to come in
contact with linings.
Fig. 9-Inspecting for Proper Lubrication
2. If working on rear brakes, lubricate parking brake
cable. NOTE: Loose adjustment may occur from an
3. On rear brakes only, lubricate fulcrum end of adjusting screw that is not properly operating.
parking brake lever and the fulcrum pin with If the lubrication in the adjusting screw of as
brake lube, then attach lever to secondary shoe sembly is contaminated or destroyed, the ad
with pin, spring washer and snap ring. justing screw should be thoroughly cleaned and
4. Before installation, make sure that lever moves lubricated.
freely fig. 8 and the adjusting screw is clean and
lubricated properly fig. 9. 5. Connect brake shoes together with adjusting

PASSENGER CAR SHOP MANUAL SUPPLEMENT


BRAKES-STANDARD 6-5

screw spring, then place adjusting screw, socket


and nut in position.
CAUTION: Make sure the proper adjusting
screw is used left hand or right hand. The
star wheel should only be installed with the
star wheel nearest to the secondary shoe and
the adjusting screw spring inserted to prevent
interference with the star wheel.
6. Secure the primary brake shoe short lining-faces
forward first with the hold-down pin and spring
using a pair of needle nose pliers. Engage shoes
with the wheel cylinder connecting links.
7. Secure the actuator assembly, override spring and
return spring on the secondary shoe.
8. Install and secure the actuator assembly and sec
ondary brake shoe with the hold-down pin and
spring using a pair of needle nose pliers.
9. Install guide plate over anchor pin.
10. Install the wire link.
NOTE: Do not hook the wire link over the
anchor pin stud with the regular spring hook
Fig. 11-Backing Plate Contact Faces
tool. This may damage the cylinder boot seals.
Place the wire link over the anchor pin stud distorted, or if strength is doubtful, install new
first, and then fasten to the actuator assembly springs.
by holding the adjuster assembly in the full
down position. 13. Hook springs in shoes using Tool J-8049 by install
ing the primary spring from the shoe over the
anchor pin and then spring from secondary shoe
over the wire link end fig. 10.
14. Pry shoes away from the backing plate and lubri
cate shoe contact surfaces with a thin coating of
brake lube fig. 11.
CAUTION: Be careful to keep lubricant off fac
ings.

15. After completing installation, make certain the


actuator lever functions easily by hand operating
the self-adjusting feature.
16. Follow the above procedure for all brakes.
17. Adjust the service brakes as outlined below, then
adjust the parking brake.

Adjustment

Although the brakes are self-adjusting, a prelimi


nary or initial adjustment may be necessary after the
brakes have been relined or replaced, or whenever the
length of the adjusting screw has been changed. The
final adjustment is made by using the self-adjusting
feature.
Fig. 10-installing Pull Back Springs

11. On rear brakes connect cable to parking brake Adjusting the Service Brakes
lever and install strut between lever and primary
1. With brake drum off, disengage the actuator from
shoe as installation is made.
the star wheel and rotate the star wheel by spin
12. If old brake pull back return springs are nicked, ning or turning with a small screwdriver.

PASSENGER CAR SHOP MANUAL SUPPLEMENT


BRAKES-STANDARD 6-6

Alternate:
a. Using the brake drum as an adjustment fixture,
turn the star wheel until the drum slides over
the brake shoes with a slight drag.
b. Turn the star wheel 1¼ turns to retract the
shoes. This will allow sufficient lining-to-drum
clearance so final adjustment may be made as
described in Step 4.
3. Install the drum and wheel.
NOTE 1: If lanced area in brake drum was
knocked out, be sure all metal has been re
moved from brake compartment. Install new
hole cover in drum to prevent contamination of
the brakes.

Fig. 12-Using Drum-to-Brake Shoe Clearance Gauge

Fig. 14-Aligning Drum Tang with Wheel Hub

NOTE 2: Make certain when installing drums


that drums are installed in the same position
as when removed with the drum locating tang
in line with the locating hole in the wheel hub
fig. 14.
4. Make final adjustment by driving and stopping
Fig. 13-Checking Brake Shoe Lining Clearance vehicle until satisfactory brake pedal height is
obtained as described under "Self-Adjusting Fea
2. Recommended: tures" earlier in this section.
a. Use special Tool J-21177, Drum-to-Brake Shoe
Clearance Gauge, to check the diameter of the CLUTCH AND BRAKE PEDAL
brake drum clearance surface fig. 12. Removal
b. Turn the tool to the opposite side and fit over
the brake shoes by turning the star wheel until 1. Disconnect clutch pedal return spring located in
the gauge just slides over the linings fig. 13. engine compartment.
c. Rotate the gauge around the brake shoe lining 2. Remove retainer and pull pin from brake pedal
surface to assure proper clearance. arm fig. 15.

PASSENGER CAR SHOP MANUAL SUPPLEMENT


BRAKES-STANDARD 6-7

BRAKE PEDAL CLUTCH PEDAL


LINKAGE LINKAGE

Fig. 15-Clutch and Brake Pedal Installation

3. Remove retainer and washer from clutch pedal Installation


push rod, and disengage push rod from clutch
pedal bracket. 1. Install one nylon bushing on clutch pedal pivot
shaft, one in right side of panel brace and one in
4. Remove retainer from right side of clutch pedal each end of brake pedal bore.
pivot shaft.
2. Position the brake pedal return spring on pedal
5. Slide the clutch pedal assembly to the left and arm, and place pedal assembly in panel brace in
remove from panel brace. Brake pedal arm and dex return spring in panel brace cutout.
tension spring will be free for removal when pivot
shaft clears panel brace. 3. Slide clutch pedal pivot shaft through panel brace
and brake pedal bore.
6. Withdraw brake pedal and all nylon bushings. 4. Install retainer in groove at end of clutch pedal
pivot shaft.
Inspection
5. Connect clutch pedal push rod to clutch pedal
1. Clean all metal parts with a good nontoxic clean bracket, and install washer and retainer.
ing solvent. 6. Position main cylinder push rod clevis to brake
2. Wipe the nylon bushings clean with a clean cloth. pedal arm, install pin and install retainer in groove
at end of pin.
CAUTION: Nylon bushings should not be treat
ed with cleansing agent of any nature. 7. Adjust brake pedal free play to 1/16 to 1h inch,
and check stop light switch position-adjust if nec
3. Inspect all nylon bushings for wear and damage. essary so that electrical contact is made when
4. Inspect all mating surfaces of bushings for wear pedal is depressed % inch.
and damage-replace parts as required. 8. Connect clutch pedal return spring.

PASSENGER CAR SHOP MANUAL SUPPLEMENT


BRAKES-METALLIC 6-8

METALLIC BRAKES
Metallic brake linings which use special heat re- Seating Metallic Linings
sistant brake springs are available as an option. Serv
ice operations are the same as for standard brakes; After the brakes have been adjusted, the following
however, when new linings are installed, the linings recommended "lining seating" is as follows:
should be seated as described below. 1. Make six to eight stops from 30 mph with moder
ate pedal pressure to aid in seating and to modu
NOTE: Brake shoes with metallic linings re-
late any tendency to dive.
quire specially finished brake drums honed to
a 20 micro-inch finish. Metallic linings are not 2. Make six to eight complete stops from maximum
recommended for service replacement on vehi- legal highway speed at approximately one mile in
des with standard brake drums that have not tervals to fully seat the linings.
been honed to specified finish.

PASSENGER CAR SHOP MANUAL SUPPLEMENT


BRAKES-BENDIX POWER 6-10

The Master-Vac power brake unit permits the use fold to check valve located on front shell; the other a
of a low brake pedal as well as less pedal effort than hydraulic connection from the main cylinder outlet
is required with the conventional nonpower hydrau directly into the hydraulic system. The unit is mounted
lic brake system. Only two external line connections on the engine side of the fire wall and connected to the
are necessary-one a vacuum connection from math- brake pedal through an auxiliary lever and rod.

MAINTENANCE AND ADJUSTMENTS


Inspections Lubrication
1. Check vacuum line and vacuum line connections The Master-Vac power brake unit is lubricated at
as well as vacuum check valve in front shell of assembly and needs no further lubrication other than
power unit for possible vacuum loss. maintaining normal reservoir fluid level. The reservoir
should be filled as described in this section, using only
2. Inspect all hydraulic lines and connections at the recommended brake fluid.
wheel cylinders and main cylinder for possible
hydraulic leaks. Bleeding Instructions
3. Check brake assemblies for scored drums, grease The power system may be bled manually or with a
or brake fluid on linings, worn or glazed linings, pressure bleeder as outlined in this section. If pressure
bleeding method is used as specified under "Standard
and make necessary adjustments.
Brakes," omit use of Tool J-9477.
4. Check the brake fluid level in the hydraulic reser Use only recommended brake fluid. Do not use
voir. The reservoir should be filled to within ½" power assist while bleeding. The engine should not
of the top of the filler cap opening. Inspect the res be running and the vacuum reserve should be re
ervoir cover for fluid leaks at gasket. duced to zero, by applying the brake several times
before starting the bleeding procedure.
5. Check for loose mounting bolts at main cylinder
and at power section. Air Cleaner Service
6. Check air cleaner filter located in the power piston The air cleaner filter used with the power brake unit
extension-replace ifiter if necessary. should be cleaned at least twice a year. To clean, re
move air cleaner element and wash thoroughly in
7. Check brake pedal for bending and misalignment cleaning solvent-allow element to dry before rein
between pedal and push rod. stalling.

SERVICE OPERATIONS
Removal main cylinder refer to applicable portion of "Standard
Brakes."
1. Disconnect push rod clevis at brake pedal arm.
1. Remove main cylinder from power section, and
NOTE: If clearance hole through fire wall is not
place main cylinder aside.
large enough, it may be necessary to remove
clevis from push rod. Note approximate loca 2. Remove main cylinder filter, piston seal assembly
tion of clevis on rod. and main cylinder push rod from front shell fig.
17-pulling the push rod from front shell will also
2. Remove vacuum hose from check valve.
remove the filter and seal assembly.
3. Disconnect hydraulic line at main cylinder. 3. Position and secure Tool J-9576-1 fig. 18 to main
4. Remove four nuts and lockwashers securing power cylinder mounting studs, and place tool and power
unit to fire wall, and remove power unit from unit in a vise. Be sure to align tool so that check
engine compartment. valve in front shell is not damaged.
4. Disconnect linkage at air valve push rod, and re
Disassembly move mounting bracket from rear shell.
The following procedure applies to the power sec 5. Remove rubbçr boot and retainer plate from
tion of the power brake unit only-for service of the rear shell.

PASSENGER CAR SHOP MANUAL SUPPLEMENT


BRAKES-BENDIX POWER 6-11

Fig. 17-Component Exploded View

1. Mounting Bracket 6. Filter Retainer 11. Diaphragm Plate 16. Grommet


2. Rubber Boot 7. Air Cleaner Filter 12. Reaction Disc 17. Check Valve
3. Retainer Plate 8. Air Valve Push Rod Assembly 13. Hydraulic Push Rod 18. Push Rod Seal
4. Bearing Seal 9. Rolling Diaphragm 14. Power Piston Return Spring 19. Main Cylinder Filter
5. Rear Sheir 10. Air Valve Lock 15. Front Shell

10. Loosen, but do not remove, the nuts on the


through bolts. The shells should begin to separate
TOOL J-9504 as the nuts are loosened. If shells do not begin to
separate, tap rear shell with a soft faced hammer.
After shells begin to separate, remove nuts from
through bolts.
CAUTION: Hold rear shell firmly when remov
ing nuts from through bolts. Pressure exerted
by internal diaphragm spring may cause rear
shell to fly off when shells are in the released
position.

11. Remove power piston from front shell, separate


TOOL J-9576-1
power piston from rear shell, and remove Tool
J-9504 from unit.
12. Disassemble power piston. See Figure 19.

A
a. Remove rolling diaphragm from the groove in
the diaphragm plate hub.
Fig. 18-Separating Shells with Tools .1-9504 and J-9576-1
b. Hold the diaphragm plate so that the push rod
is in its normal horizontal installed position,
6. Remove filter retainer from end of diaphragm depress the push rod slightly approximately
plate extension, and remove air filter element from 1/16 inch, and rotate piston so the air valve
location within the diaphragm plate extension.
lock will fall from its location in the piston hub.
NOTE: To prevent chipping of the plastic dia c. Remove the air valve push rod assembly from
phragm plate, exercise extreme caution when the piston.
removing the air filter retainer. Use a small
d. Remove the reaction disc from its location in
screwdriver or other suitable tool, ad pry at the diaphragm plate bore. Insert the main cyl
several peripheral locations until the retainer is inder push rod or other suitable tool through
freed. diaphragm plate extension and push disc from
its seat. Exercise care so as not to chip surface
7. Scribe alignment mark across surface of front and of passages in the diaphragm plate.
rear shells.
NOTE: Perform Step 13 only if seal is de
8. Position bar wrench Tool J-9504 over studs of fective and a new seal is available. Do not
the rear shell so that holes in bar wrench line up reuse seal once it has been removed from
with holes in holding fixture Tool J-9576-1. In the unit.
stall through bolts in aforementioned holes, and
tighten nuts until a slight compression is obtained. 13. Support outer surface of rear shell on blocks of
wood or other suitable material and drive out
9. Rotate Tool J-9540 until cutouts of rear shell are seal with a punch or a thin blade screwdriver. Dis
aligned with lances in front shell. card seal.

PASSENGER CAR SHOP MANUAL SUPPLEMENT


BRAKES-BENDIX POWER 6-12

applying lubricant as specified in assembly procedure,


use an approved lubricant of known quality and com
position that will not be harmful to rubber and plastic
materials.
1. Install check valve grommet in front shell-beveled
edge of grommet is to be inside shell. Dip check
valve in clean alcohol and install in grommet-
check valve stem is to be outside shell.
2. Position and secure Tool J-9576-1 fig. 18 to main
cylinder mounting studs, and place tool and front
shell in a vise. Be sure to align tool so that check
valve is not damaged.
Fig. 19-Power Piston
NOTE: If either or both of the shells are, re
1. Filter Retainer 5. Air Valve Lock placed, make sure alignment marks are trans
2. Air Cleaner Filter 6. Diaphragm Plate ferred to new shell.
3. Rolling Diaphragm 7. Reaction Disc
4. Air Valve Push Rod Assembly 3. Place rear shell on block, to back up plate around
center hole, and position bearing seal in center
14. Remove check valve from grommet; then remove hole. Use Tool J-9540 fig. 20 to seat seal in recess
grommet from front shell. of rear shell. Tool bottoms against shell when seal
15. Remove front shell and holding fixture from vise; is in place.
then remove holding fixture from front shell. 4. Assemble the power piston assembly. See Fig
ure 19.
Cleaning
a. Apply lubricant to outside diameter of dia
Use an approved nontoxic cleaning solvent to clean phragm plate and extension, to bearing surfaces
all metal parts. Use alcohol or an approved commercial of valve and plunger, and to outer edge of valve
cleaning solvent for cleaning rubber and plastic parts. poppet. Insert valve and rod assembly in exten
Immerse parts in cleaning solvent and use a hair brush sion of diaphragm plate.
to remove foreign matter. Blow out all passages, ori
b. Depress the push rod slightly, and install the
fices and valve holes. Air dry and place cleaned parts
air valve lock. Make sure the lock indexes and
on clean paper or lint-free cloth. If slight rust is found
retains the air valve.
on inside surface of power cylinder housing, polish
clean with crocus cloth or fine emery cloth, then follow c. Install the rolling diaphragm in the groove of
with a thorough cleaning. diaphragm plate hub.
The use of gasoline, kerosene, antifreeze alcohol or d. Apply lubricant to surface of reaction disc and
any other cleaner with even a trace of mineral oil will position disc in center bore of diaphragm plate.
damage rubber parts. Be particularly careful during Use main cylinder push rod to seat disc in bore.
reassembly that no grease or mineral oil comes in con Make sure disc is fully seated before removing
tact with these rubber parts. push rod.

Inspection NOTE: If reaction disc is not fully seated, it


will result in an erroneous push rod height
Carefully inspect each part for damage and wear adjustment.
inspect rubber parts for cuts, nicks and distortion.
These rubber parts are the key to control of air flow 5. Apply lubricant too ID of bearing seal and dia
and should account for the majority of trouble trace phragm bead contact surface of rear shell. Install
able to leakage. If there is any question whatever as to power piston assembly in rear shell.
serviceability of any part, replace it. 6. Position bar wrench Tool J-9504 over studs of
rear shell so that holes in bar wrench will line up
Assembly with holes in holding fixture Tool J-9576-1.
The following procedure refers to the power section 7. Place power piston return spring in front shell and
of the power brake unit only-for assembly procedure position rear shell assembly on front shell. Posi
of the main cylinder, refer to applicable portion of tion rear shell so that when shells are locked
"Standard Brakes." scribe marks on front and rear shells will be in
During assembly, make sure all parts are free of alignment.
foreign material before applying lubricant. If there is 8. Depress rear shell assembly and install through
any doubt of cleanliness, rewash and air dry. When bolts to the fixture. Tighten through bolts suffi

PASSENGER CAR SHOP MANUAL SUPPLEMENT


BRAKES-BENDIX POWER 6-13

Fig. 21-Adjustment of Push Rod

16. After push rod adjustment is correct, assemble


main cylinder to front shell and securely tighten
retaining nuts.

2’o -4--NO.l5ORlo
U.S.S. GAUGE
SHEET STEEL

Fig. 20-Installing Piston Bearing Seal

ciently to bring scallops on rear shell slightly be


low lances on front shell. Rotate Tool J-9504 until
scribe marks on front and rear shells are in align
ment. Remove Tool J-9504 from unit. Fig. 22-Push Rod Gauge

9. Install air cleaner element and retainer to piston Installation


extension.
1. Mount the power brake assembly in place and
10. Install boot retainer and boot over piston exten install four attaching nuts and lockwashers. Be
sion and secure boot to air cleaner retainer. certain to place push rod through cutout in fire
11. Align and install mounting bracket to rear shell. wall.
Connect linkage to air valve push rod. 2. Attach vacuum line to check valve.
12. Remove unit from holding fixture Tool J-9576-1. 3. Secure hydraulic line to main cylinder.
13. Apply lubricant sparingly to the hydraulic push 4. Adjust push rod clevis to brake pedal assembly.
rod, keeping lubricant away from adjusting screw Adjust pedal height by means of clevis on brake
end of rod. Guide push rod into center bore of pedal push rod at pedal. Pedal height is obtained
power piston until it is fully seated against reac by measuring from floor covering at toe pan to top
tion disc. of pedal pad. Correct heights are:

14. Install seal and main cylinder filter and press filter Biscayne and Bel Air 4/8"

and seal into front shell until seal is bottomed in Impala 4%"
recess of shell. NOTE: Check operation of stop light after ad
15. Place Tool J-7723-01 over the push rod so that it justing pedal height.
fits between studs on front shell fig. 21. Gauge 5. Bleed brakes as outlined in this section.
should be parallel to studs and resting on surface
of front shell. Cutout portion of gauge should just NOTE: After completing the bleeding opera
match height of push rod. Any variation may be tion, make sure reservoir fluid level is at correct
compensated for by turning adjusting screw. height. The reservoir should be filled to ½ inch
of the filler cap opening.
NOTE: If push rod height adjustment gauge is
not available, the required dimensions for fab 6. Check operation of the brakes as outlined in this
rication are given in Figure 22. section.

PASSENGER CAR SHOP MANUAL SUPPLEMENT


BRAKES-MORAINE POWER 6-14

MORAINE POWER BRAKES


INDEX
Page Page
General Description. 6-14 Disassembly 6-15
Maintenance and Adjustments 6-15 Cleaning 6-16
Inspections 6-15 Inspection 6-17
Lubrication 6-15 Assembly
Bleeding Instructions 6-15 6-17
Air Cleaner Service 6-15 Installation 6-18
Service Operations 6-15 System Tests and Diagnosis 6-19
Removal 6-15

GENERAL DESCRIPTION
The Moraine power brake unit is composed of two the floating control valve assembly. The reaction mech
main sections-the vacuum power cylinder fig. 23 and anism consists of a hydraulic piston reaction plate and
the hydraulic main cylinder. a series of levers. The vacuum check valve is located
on the forward shell of the power cylinder and pro
The vacuum power cylinder contains the power pis
ton assembly, which houses the control valve and vides a hose connection to accommodate the vacuum
reaction mechanism, and the power piston return line. The air cleaner element is contained within the
spring. The control valve is made of the air valve and extended portion of the control valve housing.

13
14

15
/ 16

17
18

20 9

27 26 25

Fig. 23-Moraine Vacuum Power Cylinder

1. Front Shell 9. Support Plate 16. "0" Ring 22. Control Valve Return Spring
2. Gasket 10. Support Plate Retaining Screw 17. Air Valve Return Spring 23. Spring and Valve Seat
3. Seal Retainer 11. Power Piston Insert 18. Air Valve and Push Rod 24. Control Valve Diaphragm
4. Main Cylinder Push Rod 12. Rear Shell Assembly 25. Diaphragm Support
5. Push Rod Adjusting Screw 13. Power Piston 19. Air Cleaner Element 26. Floating Control Valve
6. Support Plate Seal 14. Reaction Lever 20. Rubber Boot 27. Insert Seals
7. Power Piston Return Spring 15. Rubber Bumper 21. Power Piston Bearing 28. Power Piston Rolling Diaphragm
8. Hydraulic Reaction Plate

PASSENGER CAR SHOP MANUAL SUPPLEMENT


BRAKES-MORAINE POWER 6-15

MAINTENANCE AND ADJUSTMENTS


Inspections Lubrication
1. Check vacuum line and vacuum line connections The Moraine power brake unit is lubricated at as
as well as vacuum check valve in front shell of sembly and needs no further lubrication other than
power unit for possible vacuum loss. maintaining normal reservoir fluid level. The reser
voir should be filled as described in this section, using
2. Inspect all hydraulic lines and connections at the only recommended brake fluid.
wheel cylinders and main cylinder for possible
hydraulic leaks.
Bleeding Instructions
3. Check brake assemblies for scored drums, grease The power system may be bled manually or with a
or brake fluid on linings, worn or glazed linings, pressure bleeder as outlined in this section. Use only
and make necessary adjustments. recommended brake fluid. Do not use the power assist
while bleeding. The engine should not be running and
4. Check the brake fluid level in the hydraulic reser
the vacuum reserve should be reduced to zero by
voir. The reservoir should be filled to within ¼
applying the brake several times before starting the
inch of the reservoir rim.
bleeding procedure.
5. Check for loose mounting bolts at main cylinder
and at power section. Air Cleaner Service
6. Check air cleaner filter in power piston extension, The air cleaner filter used with the power brake unit
and replace filter if necessary. should be cleaned at least twice a year. To clean,
slide the rubber boot rearward, and remove the filter.
7. Check brake pedal for binding and misalignment Wash the filter thoroughly in cleaning solvent and
between pedal and push rod. allow to dry before reinstalling.
4

SERVICE OPERATIONS
Removal 3. Disconnect hydraulic line at main cylinder.
1. Disconnect clevis at brake pedal assembly. 4. Remove four nuts and lockwashers securing power
NOTE: If clearance hole through fire wall is not unit to fire wall and remove power unit from en
large enough, it may be necessary to remove gine compartment.
clevis yoke from push rod. Note approximate
location of yoke on rod. Disassembly
2. Remove vacuum hose from vacuum check valve. The following procedure applies to the power section

/ I
O6
7.’/
9

Fig. 24-Component Exploded View

1. Rubber Boot 5. Power Piston Return Spring 8. Check Valve


2. Bearing Seal 6. Front Shell 9. Support Plate Seal Retainer
3. Rear Shell 7. Grommet Assembly
4. Power Piston Assembly

PASSENGER CAR SHOP MANUAL SUPPLEMENT


BRAKES-MORAINE POWER 6-16

of the power brake unit only-for service of the main 6. Support power piston so that it will remain in an
cylinder refer to applicable portion of "Standard upright position main cylinder push rod up. Re
Brakes." move hex head screws that secure support plate
1. Remove main cylinder from power section of to power piston, and remove support plate from
power brake unit and place main cylinder aside. piston assembly fig. 26.
2. Place main cylinder retaining nuts on main cylin 7. Remove power piston rolling diaphragm from the
der mounting studs, and position power section support plate assembly. The main cylinder push
in vise so that jaws of vise will bear against re rod can be removed from support plate, and, if
taining nuts. necessary, reaction plate may be removed by
pressing from push rod. The adjusting screw may
NOTE: Scribe alignment marks on top center also be removed from push rod.
of front and rear shell to facilitate reassembly. 8. Remove three reaction levers from their seats in
the power piston insert, and remove air valve
3. Disconnect linkage at air valve push rod, and posi return spring from the counterbore of air valve.
tion linkage so that a metal bar can be inserted 9. Remove power piston insert then remove two
through access holes in mounting bracket. seals from OD of insert.
4. With metal bar in position, press down on bar and 10. Lift air valve and push rod assembly fig. 17
rotate rear shell counterclockwise until rear shell from power piston and remove snubber and "0"
is separated from front shell. ring from air valve.
11. Push the floating control valve assembly from its
CAUTION: Care must be exercised not to dam
position in the center of power piston. Disassem
age or loosen studs in shell. Also, take care
ble floating control valve. Removal of floating con
that no pressure is brought to bear on plastic
trol valve assembly exposes floating control valve
power piston extension.
spring and seat.
5. Remove rubber boot from power piston extension 12. Remove the power piston return spring from the
and separate power piston from rear shell. Remove front shell, and remove front shell from vise.
air filter element from power piston extension, 13. Remove the suport plate seal retainer from the
and remove power piston bearing from the rear center of the front shell. Disassemble retainer by
shell fig. 24. removing gasket and seal.
14. Pull check valve from grommet in front shell, and
CAUTION: Extreme care must be taken in han
remove grommet.
dling the diaphragm of the power piston as
sembly fig. 25. The diaphragm should be
guarded against grease, oil, foreign matter and Cleaning
must be protected from nicks, scratches and Use "Declene" or clean brake fluid to clean all metal,
gouges. plastic and rubber parts of the power cylinder. Im

3 4 5 9 10 11 12 13 14 15 16 17 22

I QJ3Gi
16 7 81

I,
FIg. 25-Power Piston Exploded View

1. Air Cleaner Element 7. Diaphragm Support 13. Insert Seal 18. RoIling Diaphragm
2. Power Piston 8. Floating Control Valve 14. Insert 19. Support Plate
3. Control Valve Return Spring 9. Air Valve Push Rod Assembly 15. Reaction Levers 20. Retaining Screw
4. Spring and Valve Seat 10. ‘0" Ring 16. Insert Seal 21. Hydraulic Push Rod
5. Floating Control Valve Assembly 11. Rubber Bumper 17. Reaction Plate 22. Adjusting Screw
6. Diaphragm 12. Air Valve Return Spring

PASSENGER CAR SHOP MANUAL SUPPLEMENT


BRAKES-MORAINE POWER 6-17

If there is any suspicion of contamination or evi


dence of corrosion, completely flush hydraulic brake
system as described in this section. Failure to clean
hydraulic system can result in early repetition of
trouble.
Use of gasoline, kerosene, antifreeze alcohol or any
other cleaner with even a trace of mineral oil will
damage rubber parts. be particularly careful during
reassembly that no grease or mineral oil comes in con
tact with these rubber parts.

Inspection
Wipe cleaning fluid from all parts and carefully in
spect each part for damage and wear. Inspect rubber
parts for cuts, nicks and, distortion. These rubber parts
are the key to control of air flow and should account
for the majority of trouble traceable to leakage. If
there is any question whatever as to serviceability of
any part, replace it.

Assembly
Be sure that all parts are clean. If there is any doubt
of cleanliness, rewash and air dry. Lubricate rubber
parts with an approved rubber lubricant. Lubricate
all plastic and metal friction points with an approved
lubricant.
Fig. 26-Disassembling Power Piston 1. Install power piston bearing in rear shell so that
the large flange is outside fig. 24. Lubricate the
grooves in the ID of the power piston bearing.
2. Insert check valve grommet in front shell cutout,
and position check valve in grommet.
3. Press reaction plate over the small, knurled end
of main cylinder push rod until it rests against
shoulder, and install adjusting screw in taped end
of push rod.
4. Position push rod through support plate so that
reaction plate lies against support plate.
5. Place power piston in a vise so that extension is
down. Do not clamp piston.
6. Place floating valve spring and spring seat in cen
ter of piston.
7. Assemble floating valve diaphragm over flanged
hub of floating control valve. Flat surface of dia
Fig. 27-Removing Air Valve Push Rod Assembly phragm will be on side opposite rubber face of
floating control valve. Insert diaphragm plate
1. Insert Seals 4. Reaction Levers
2. Insert 5. Air Cleaner Element under lip of diaphragm.
3. Air Valve Return Spring
8. Press floating control valve and diaphragm as
sembly into the power piston so that control valve
merse parts in cleaning fluid and use a hair brush to bears against spring seat and compress spring.
remove foreign matter. Blow out all passages, orifices
and valve holes. Air dry and place cleaned parts on NOTE: As the floating valve assembly is pressed
clean paper or lint-free cloth. If slight rust is found on into power piston, make sure diaphragm is not
inside surface of power cylinder housing, polish clean distorted.
with crocus cloth or fine emery cloth, then follow with
a thorough cleaning. 9. Install "0" ring and snubber on air valve, and
Dirt is the major cause of trouble and wear in serv position push rod through floating control valve
ice. Be certain to keep parts completely clean until and into piston extension so that push rod passes
reassembly. through the loading slot in extension fig. 27.

PASSENGER CAR SHOP MANUAL SUPPLEMENT


BRAKES-MORAINE POWER 6-18

10. Assemble seals to insert and position insert over 24. Position rubber boot over push rod and power pis
air valve. Reaction lever locations in insert must ton bearing flange.
be visible when installing insert. 25. Connect linkage to air valve push rod.
11. Place air valve return spring in counterbore of air 26. Remove unit from vise and remove nuts from
valve. Position the ears of the reaction levers in main cylinder mounting studs.
the molded locations in the piston insert and rest 27. Place power unit in a vise or fixture so that the
small ends of levers on return spring. main cylinder push rod is up.
12. Place the unfolded diaphragm over the support
28. Place Tool J-7723-01 over the push rod so that it
plate so that second bead is on outside wall. Posi
fits between studs on front shell fig. 21. Gauge
tion the support plate on power piston, making
should be parallel to studs and resting on surface
sure that the beaded edge of diaphragm is located
of front shell. Cutout portion of gauge should just
between flange on support plate and flange on edge
of power piston. match height of push rod. Any variation may be
compensated for by turning adjusting screw. If
13. Align screw holes in support plate with taped support plate seal retainer was used in Step 23,
holes in power piston. Be sure that reaction levers remove it for gauging procedure.
maintain their positions in seats of power piston
insert. NOTE: If push rod height adjustment gauge is
14. Depress support plate until support plate bottoms not available, the required dimensions for fab
on insert gasket. Hold support plate in this de rication are given in Figure 22.
pressed position and finger tighen the support plate 29. Place support plate seal in support plate seal re
retaining screws. tainer’ so that flat surface of seal lies against bot
15. Torque support plate retaining screws to 80-100 tom of retainer. Place gasket on OD of seal re
inch pounds. tainer and insert retainer in front shell cutout
16. Wrap the flat piece of filter material around push so that gasket is between front shell and retainer
rod and slide filter into power piston extension. flange.
17. Place main cylinder retaining nuts on main cyl 30. Position main cylinder to power cylinder. Make
inder mounting studs. Position power section in sure filter is installed in main cylinder. Install
vise so that jaws of vise will bear against retain lockwashers and nuts and torque to 15-20 foot
ing nuts. pounds.
18. Position power piston return spring in the front
Installation
shell.
19. Insert power piston, air valve push rod first, into If linkage was removed, proceed as follows:
the rear shell until the piston extension passes 1. Place one operating lever on collar. Tap into place
through piston bearing. until it seats against shoulder. Install second oper
20. Fold the rolling diaphragm back over rear shell ating lever.
and apply talcum powder or rubber lubricant to 2. Place the lever and collar in position and install
beaded portion of diaphragm. pivot pin and cotter pin.
21. Position rear shell and power piston assembly to
front shell. Make sure support plate extension goes NOTE: The large diameter of collar must be on
through power piston spring. the inboard side of mounting bracket. The pivot
pin can only be installed from outer side of
22. Rotate the rear shell assembly to assure that when mounting bracket.
the shell is in the locked position, the scribe mark
will be in line with the scribe mark on the front 3. Place one wave wash on inner side of outer oper
shell. ating lever over upper hole, and install clevis
23. Place a metal bar through the access holes in pin, flat washer and cotter pin.
the mounting bracket; press down on metal bar 4. Place one wave washer on inner side of outer
and check to be sure that bead on edge of rolling operating lever over middle hole, and install
diaphragm is positioned correctly between the clevis pin, flat washer and cotter pin to brake
shells. If this is satisfactory, apply additional pedal push rod.
downward pressure and rotate rear shell clockwise If linkage was not removed, omit Steps 1-4, and
into locked position. proceed with Step 5.
NOTE: If unit is not easily locked, hold shells 5. Mount the power brake assembly in place and in
together and apply vacuum to check valve in stall four attaching nuts and lockwashers. Be cer
front shell. Do not put pressure on power pis tain to place push rod through cutout in fire wall.
ton extension. Support plate seal retainer must
be installed if vacuum assist is necessary. See 6. Attach vacuum line to check valve.
Step 29 for installation. 7. Secure hydraulic line to main cylinder.
PASSENGER CAR SHOP MANUAL SUPPLEMENT
BRAKES-MORAINE POWER 6-19

8. Attach push rod clevis to brake pedal assembly. Biscayne and Bel Air 4/8"

Adjust pedal height by means of clevis on brake Impala 4%"


pedal push rod at pedal. Pedal height is obtained NOTE: Check operation of stop light after ad
by measuring from floor covering at toe pan to top justing pedal height.
of pedal pod. Correct heights are: 9. Bleed brakes as outlined in this section.

SYSTEM TESTS AND DIAGNOSIS


SYSTEM TESTS b. Bound Up Pedal Mechanism
1. Road test brakes by making a brake application c. Power Brake Unit Trouble
at about 20 mph to determine if vehicle stops 1. Jammed air valve.
evenly and quickly. If pedal has a spongy feel 2. Vacuum leaks in unit caused by loose support
when applying the brakes, air may be present plate screws, faulty air valve seal or support
in the hydraulic system. Bleed system as de plate seal. Also, a damaged floating control
scribed in this section. valve, bad seal of main cylinder or mounting
2. With engine stopped and transmission in neutral, studs. bad seal of the diaphram between
apply brakes several times to deplete all vacuum shells or at power piston. Faulty power piston
reserve in ths system. Depress brake pedal, hold insert seal rings or check valve grommet.
light foot pressure on pedal and start engine. If 3. Defective rolling diaphragm.
the vacuum system is operating, pedal will tend
4. Restricted air ifiter element.
to fall away under foot pressure, and less pressure
will be required to hold pedal in applied position. 5. Worn or badly distorted reaction plate or levers.
If no action is felt, vacuum system is not func 6. Cracked or broken power piston or support plate.
tioning.
3. Stop engine and again deplete all vacuum reserve Grabby Brakes Apparant On-and
in system. Depress brake pedal and hold foot pres Off Condition
sure on pedal. If pedal gradually falls away under
a. Power brake unit valve trouble.
foot pressure, the hydraulic system is leaking.
1. Reaction diaphragm leakage.
4. If the brake pedal travels to within 1" of the toe-
board, brakes require adjustment or brake shoes 2. Sticking air valve.
require relining. 3. Worn or distorted levers or plate.
5. Start engine. With brakes off, run to medium
speed and turn off ignition, immediately closing Pedal Goes to Floor Or Almost to Floor
throttle. This builds up vacuum. Wait no less than a. Fluid in reservoir needs replenishing.
90 seconds, then try brake action. If not vacuum
b. Power brake hydraulic leakage.
assisted for three or more applications, vacuum
check valve is faulty. 1. Defective primary or secondary cup.
2. Cracked main cylinder casting.
DIAGNOSIS 3. Leaks at wheel cylinder, brake pipes or con
The same types of brake trouble are encountered nections.
with power brakes as with standard brakes. Before c. Faulty main cylinder check valve.
check of power brake system for source of trouble, d. Main cylinder compensating port restricted.
refer to "Troubles and Remedies" of standard brakes
e. Brakes need adjustment.
in this section. After these possible causes have been
eliminated, check for cause as outlined below:
Brakes Fail to Release
Hard Pedal a. Faulty hydraulic check valve.
a. Vacuum Failure Due to b. Blocked passage in power piston.
c. Air valve sticking shut.
1. Faulty vacuum check valve.
d. Broken piston return spring.
2. Collapsed vacuum hose to manifold.
e. Broken air valve spring.
3. Plugged or loose vacuum fittings. f. Tight pedal linkage.

PASSENGER CAR SHOP MANUAL SUPPLEMENT


BRAKES-MORAINE POWER 6-20

SPECIAL TOOLS

Fig. 28-Brake Special Tools

1. J-9540 Vacuum Power Cylinder 2. J.9504 Vacuum Power Cylinder 3. J.9576.1 Vacuum Power Cylinder 4. i-9477 Pressure Bleeder Adapter
Seal Installer Spanner Wrench Holder and Compressor 5. J.21 177 Drum-to-Brake Shoe
Clearance Gauge

PASSENGER CAR SHOP MANUAL SUPPLEMENT

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