Power brakes operate just as standard brake systems except in the actuation of the master cylinder pistons. A vacuum diaphragm is located on the front of the master cylinder and assists the driver in applying the brakes, reducing both the effort and travel he must put into moving the brake pedal.
The vacuum diaphragm housing is connected to the intake manifold by a vacuum hose. A check valve is placed at the point where the hose enters the diaphragm housing, so that during periods of low manifold vacuum brake assist vacuum will not be lost.
Depressing the brake pedal closes off the vacuum source and allows atmospheric pressure to enter on one side of the diaphragm. This causes the master cylinder pistons to move and apply the brakes. When the brake pedal is released, vacuum is applied to both sides of the diaphragm, and return springs return the diaphragm and master cylinder pistons to the released position. If the vacuum fails, the brake pedal rod will butt against the end of the master cylinder actuating rod, and direct mechanical application will occur as the pedal is depressed. The hydraulic and mechanical problems that apply to conventional brake systems also apply to power brakes, and should be checked for if the tests below do not reveal the problem. Test for a system vacuum leak as described below:
- Operate the engine at idle with the transmission in Neutral without touching the brake pedal for at least one minute.
- Turn off the engine, and wait one minute.
- Test for the presence of assist vacuum by depressing the brake pedal and releasing it several times. Light application will produce less and less pedal travel, if vacuum was present. If there is no vacuum, air is leaking into the system somewhere.
- Test for system operation as follows:
- Pump the brake pedal (with engine off) until the supply vacuum is entirely gone.
- Put a light, steady pressure on the pedal.
- Start the engine, and operate it at idle with the transmission in Neutral. If the system is operating, the brake pedal should fall toward the floor if constant pressure is maintained on the pedal.
Power brake systems may be tested for hydraulic leaks just as ordinary systems are tested, except that the engine should be idling with the transmission in Neutral (manual) or Park (automatic) with the wheels blocked throughout the test.
REMOVAL & INSTALLATION
- Remove the master cylinder.
- Disconnect the vacuum line from the booster.
- Remove the pin connecting the power brake operating rod and the brake lever.
- Unbolt and remove the booster.
- Replace the packing on both sides of the booster-to-firewall spacer with new packing.
- If the check valve was removed, make sure the direction of installation marking on the valve is followed.
- Install the booster and master cylinder. Torque the booster-to-firewall nuts to 6-9 ft. lbs. (72-108 inch lbs.) Torque the master cylinder-to-booster nuts to 6-9 ft. lbs.