Dodge CUSTOM ROYAL 1957 User manual

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DODGESERVICEMANUAL
ENGINESERIALNUMBER
F¡g. 1—EngineNumber—(6Cyl.)
Vehicle Engine Number Location
Theenginenumberisstampedona bossontheleft
frontsectionofthecylinderblock(6cylinder)andon
abossatthecenterofthecylinderblockdirectlybe-
hindthewaterpumpandnexttotheoilfillertubeon
theV-8,asshowninFigures1and2.
Vehicle Serial Number Location
Thevehicleserialnumberislocatedona platewhich
isattachedtotheleftfrontdoorhingepillar"A"post,
asshowninFigure3.
PowerF¡ite and TorqueFlite Transmission
Number Location
ThePowerFliteandTorqueFliteTransmissionserial
numberandbuildingdateisstampedona bossdirectly
abovetheoilfillertubeconnectiontothetransmission
oilpan,asshowninFigure4.
Fig. 3—SerialNumber
TRANSMISSIONSERIALNUMBER
OILPAN
Fig. 4—TransmissionNumber54x807
Rear Axle Gear Ratio Number Location
The rearaxlerationumberisstampedona bossdirectly
underthefillerplugonthecarrierhousing,asshown
inFigure5.
Generator, Voltage Regulator and
Distributor Number
Thegenerator,voltageregulatoranddistributornum-
berareshownonplatesattachedtotheunits.Check
beforereplacing.
54x810
Fig. 2—EngineNumber—<V-8)
F¡g. 5—RearAxleRatio
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BRAKES-SERVICE
BRAKESCONTENTSPar. Page
SERVICEBRAKES — 3
POWERBRAKES(PistonType) — 15
SERVICEINFORMATION
AdjustingBrakes 1110
AdjustingHandBrake(ExternalType) 1412
AdjustingHandBrakeCable(ExternalType) 1512
Bleeding the BrakeSystem 9 10
CyclebondBrakeLining 1815
GeneralInformation — 4
GrindingRecommendations 3 6
Inspecting the BrakeShoes 2 6
InspectingSupportPlates 6 9
Installing the BrakeShoes 4 7
InstallingSupportPlates and WheelCylinders 8 9
Removing the BrakeShoes 1 5
RemovingtheSupportPlatesandWheelCylinders 5 8
ServicingHandBrake(ExternalType) 1312
ServicingHandBrake(InternalType) 1614
ServicingHandBrakeCable(InternalType) 1714
ServicingMasterCylinder 1212
ServicingWheelCylinders 7 9
Test for FluidContamination 1010
SERVICE
CONDITIONS m^
POSSIBLECAUSES T,
Improperbrakefluid
Airinsystem
Swollenrubberparts
Brokenorcrackeddrum
Loosewheelbearings
Loosepedalmountingbracketormastercylinder
Incorrectshoeadjustment
Mastercylinderpushrodadjustment
Leaking or brokenlines
Loosecylinderbleedscrews
Drum"out of round"
Hardspots on drum
Improperorglazedlining
Sprungshoes
Water,mud,dirtindrums
Tornorlooselining
Weakpedalreturnspring
Loosesupportplatebolts
Bentmastercylinderpush rod
Spongy-Rubbery
Pedal
•
•
•
•
DIAGNOSIS
Chattering
Squealing
•
•
•
i
•
NoReserve
•
•
•
•
Pressure
Loss
•
•
•
Hard
Pedal
•
•
•
Pumping Necessary
•
•
•
Binding
•
No
Pedal
Return
•
•
Grab
or
Lock
•
•
•
•
Side
Pull
•
•
•
•
•
Overheating
•
•
•
•
Fading
•
•
Dragging
•
•
•
•
•
•
•
•
•
Pulsating
•
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DODGESERVICEMANUAL
SERVICEDIAGNOSIS-(Cont¡nued)
CONDITIONS mþ>
POSSIBLECAUSES X,
Pedallinkage
Pushrods not engaged in brakeshoeslots
Axleshaft or axleshaft to dustshieldrun-out
Loosespring"U"bolts
Brakeshoeguideshaveinsufficienttension
Spongy-Rubbery Pedal
Chattering
Squealing No
Reserve
Pressure
Loss
Hard
Pedal
•
Pumping Necessary
Binding
•
NoPedal
Return
•
Grab
or
Lock
Side
Pull
Overheating
•
Fading
Dragging
Pulsating
•
•
•
•
SERVICEINFORMATION
PROCEDURES
GENERALINFORMATION
A new type of servicebrake is used on thenew Dodge
models and is known asthe CenterPlaneBrake. The
mainfeatures of this new brakeare;lesspedaleffort
fora givenstop;morepedalreserve;less
brakefade; longerlininglife;smootheroper-
ation;lessfrequentadjustmentand,when
needed,simpleservicingoperations.
Thebrakeshoedesign and method of support are the
maindifíerencesbetween the centerplanebrake and
theconventionalbrakes, as shown in Figures1,2, 3, and
4. Additionaldifíerences are: fullfloating,shoes,rather
thanfixedanchorshoes;uniformpressureshoes,that
havebeendesigned to matchdrumdeflection; a center
planesupport of theseshoes,between two steelplates,
and, an increasedwidth of lining.
Thecenterplanebrakeshoeshavecontouredwebs,
(seeFigure 1) whichallowgreaterflexibility ofthe
TOE
shoes, causing the drum and shoes to match in rigidity
togivesimilardeflections atany section.Thiseliminates
highpressures at thetoeand heel of the shoe,when the
drumbecomesmoreovalshapedthan the shoesduring
hard or heavybreakingeffort.Thisactionallows uni-
formpressuredistributionover the fulllength ofthe
shoelining arcand results in lesspedaleffort fora
givenstop.
Thebrakingaction is centralizedbetween thetwo
supportplates, as shown in Figure2.Theseplatesalign
WHEELBRAKE
CYLINDER
WHEELBRAKE
CYLINDER
CONNECTING
TUBE
CONSTANT
WEBDEPTH
CONTOURED
WEBDEPTH
HEEL
CONVENTIONALBRAKECENTER-PLANEBRAKE
55X712
F¡g. i—CenterPlane and ConventionalBrakeShoes
BRAKE
CYLINDER
COOLINGFINS
OUTER
SUPPORT
PLATE
INNER
SUPPORT
PLATE
WHEELSTUD
BRAKESHOE
WEB
BRAKELINING
ADJUSTING
CAM
BRAKE
SHIELD
BRAKE
DRUM
55X713
F¡g. 2—CenterPlaneBrake(SectionalView)
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BRAKES-SERVICE
CYLINDERASSEMBLY
ADJUSTING CAM
SPRINGLOOP
RETURNSPRING
(5COILS)
SPRINGLINK
SEAL
ANCHORS
Fig. 3—CenterPlaneBrakeAssembly(LeftFront)57x47
theshoesandholdtheanchorsandwheelcylinders.The
applyingforcefrom the piston andthe shoereturn
springsareallin a centerplane.Thusƒtheshoesdonot
tend to twist,(resulting in unevencontact) butare
aligned ina single,centrallylocatedplane.
Siderattle ofthe shoes is controlled by guides, as
showninFigures3and4.Theguidesmaintainconstant
pressureagainsttheweb of theshoes.
Thewheelcylindersoperate in thesamemanner as
theconventionalcylinders, but,are mounted onthe
brakesupportplate.
Selfenergizingaction is effective onall frontbrake
shoesandtherearbrakefrontshoe,whenthevehicle
istravelingforward; and selfenergizingaction onthe
rearshoeoftherearbrakes,whenthevehicleistravel-
inginreverse.
1. REMOVING THE BRAKESHOES
Should it becomenecessarytoremovethebrakeshoes
forrelining or completereplacement,refertoFigures 3
or4,thenproceed as follows:
Removing the Front Brake Shoes
(1)Blockthebrakepedal to preventanydownward
movement of thepedal.
(2)Removethefrontwheelanddrumasanassembly,
afterbacking off theadjustingcams.
(3)UsingToolC-3462,removetheshoereturnsprings,
asshowninFigure5.Theend of theToolshouldbein-
sertedbetween the springlink andthe supportplate.
Withthetoolcamslotengaging the springhook,turn
handle ofthe tool to disengage the spring. DO NOT
USE BRAKESPRING PLIERS, OR DAMAGE
TOTHE LININGWILL RESULT.
(4) Turn the brakeshoeguideretainer ¼ turn, then
remove the retainer and guide, as shown in Figure 6.
Thelipontheendofguide,isusedforposi-
tioningtheguideontheoutersupportplate.
UPPERCYLINDERASSEMBLY
ADJUSTING CAM
RETURNSPRING,
(4COILS)
RETAINER
GUIDESPRING
ANCHOR
SUPPORTPLATE
/SPRINGLINK
ANCHOR
Fig. 4—CenterPlaneBrakeAssembly(Rear)
RETURNSPRING
(4COILS)
ADJUSTING CAM
LOWERCYLINDERASSEMBLY
SHIELD
57x46
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DODGESERVICEMANUAL
TOOL
57x49
Fig. 5—RemovingBrakeShoeReturnSpring
GUIDESPRING
RETAINER
57x48
Fig. 6—Removing or InstallingShoeGuides
(5)Slidetheshoesfrombetweenthesupportplates,
asshowninFigure7.
Removing the Rear Brake Shoes
Withthebrakepedalblockedtopreventanydownward
movement,proceedasfollows:
(1)Backofftheadjustingcams.
(2)Removetherearwheelasanassembly.Using
puller.ToolC-845,removetherearwheeldrum.
(3)UsingToolC-3462,removetheshoereturnsprings,
asshowninFigure8.Theendofthetoolshouldbein-
sertedbetweenthespringlinkandthesupportplate.
Withthetoolcamslotengagingthespringhook,turn
handleoftooltodisengagethespring.DONOTUSE
BRAKESPRINGPLIERS,ORDAMAGETO
THELININGWILLRESULT.
(4)Turnthebrakeshoeguideretainer¼ turn,then
removetheretainerandguide.(RefertoFigure6).The
lipontheendofguide,isusedforpositioning
theguideontheoutersupportplate.
(5)Slidetheshoesfrombetweenthesupportplates.
(RefertoFigure7.)
2. INSPECTING THE BRAKESHOES
Wipeorbrushclean(dry)themetalportionsofthebrake
shoes. Examinetheliningcontactpatterntodetermine
iftheshoesaretrue.Theliningshouldshowcontact
acrosstheentirewidth,extendingfromheeltotoe.Shoes
showingcontactononlyonesideshouldbediscarded.
Shoeshavingsufficientliningbutlackofcontactattoe
andheel,shouldbecheckedforproperunder-drum
diametergrind.
3. GRINDINGRECOMMENDATIONS
Brakeshoelining—Newliningshouldbechecked
andgroundto.010to.024inchunderthedrumdiameter
(ifnotpre-ground)ona machinehavinga cylindrical
grindingwheel.
57x5057x51
Fig. 7—RemovingShoesfromSupportPlates8—RemovingShoeReturnSpring(RearWheel)
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BRAKES-SERVICE
Drumrefacing—Measurethedruminsidediameter
with an accurategauge.Drumdiameterservicelimit
should not exceed.004inch outof round. Ifthe drum
diameter isin excess of .004inch, the drumshould be
refaced.Donotremovemorethan.030inchof
metalduringtherefacingoperation.Thedrum
diametermeasurementisthentransferredtothegrinder
andtheliningground to therequiredclearance of .010
to.024inch,underdrumdiameter.
Thegrinding of brakeliningsneedonly be done if
thecyclebondprocess is done inthe dealership.
4.INSTALLING THE BRAKESHOES
Installing the Front Brake Shoes
Beforeinstalling the frontbrakeshoes,apply a light
coat of lubriplate on theshoewherever it contacts the
supportplate,thenproceed as follows:
(1)Slide the brakeshoesintopositionbetween the
supportplates. Be sure the ends ofthe cylinder
pushrodsengagethetoeend of theshoesprop-
erly(SeeFigure 7).
(2)Insertthefourcoilreturnsprings in thehole in
thebrakeshoewebs.
(3)Using the tapered endof ToolC-3462, as shown
inFigure 9, attach the returnsprings tothe links. Be
surethatthelongend of thespring is hooked
into thewebofthe shoes to prevent the coil
ofthespringcontactingtheshoe.
(4)Checkthetensionofthebrakeshoereturnsprings.
Thespringtensioncan be checked by hooking a scale
atthetoe of theshoeandpulling in thedirection of pis-
tonmovement. The scaleshouldreadfrom 35to45
pounds at theinstantthetoe of thebrakeshoemoves.
Adialindicatormay be used to indicatemovement in
place ofa scale.
(5)Lubricate the brakeshoeguidecontactingareas
ontheshoeswithlubriplate,theninstallguidesandre-
tainers(Refer to Figure6.) Be sure the positioning
lipofthe guideslidesinto the hole in support
plate.
(6)Install the drum, and wheel and tireassembly,
afterbacking offthe adjustingcams.Adjust the front
wheelbearings, as described inthe FrontSuspension
Section.
(7)Adjustthebrakes, as described in Paragraph 11
ofthisSection.
Installing the Rear Brake Shoes
Beforeinstallingtherearbrakeshoes,apply a lightcoat
oflubriplate on theshoewherever it contacts the sup-
portplate,thenproceed as follows:
(1)Slide the brakeshoesintopositionbetween the
supportplates. Be sure the ends ofthe cylinderpush
rodsengage thetoeendofthe shoesproperly. (See
Figure7.)
(2)Insertthefivecoilreturnsprings in theloop of
thetable of theshoes, as shown in Figure10.
(3)Usingthetaperedend of ToolC-3462, as shown in
Figure10,throughthespringlink,attachthesprings to
thelink.
(4)Lubricate the brakeshoeguidecontactingareas
ontheshoeswithlubriplate,theninstallguidesandre-
tainers. (Refer to Figure6.) Be surethepositioning
lip ofthe guideslidesinto the hole in support
plate.
(5)Checkthetensionofthebrakeshoereturnsprings.
Thespringtensioncan be checked by hooking a scale
atthetoe of theshoeandpulling in thedirection of pis-
tonmovement. The scaleshouldreadfrom 35to45
pounds at theinstantthetoe of theshoemoves. A dial
indicatormaybeusedtoindicatemovementinplaceof
ascale.
(6)Install the drum,wheel and tireassembly,after
backing off theadjustingcams.
LOOPTOOL
57x53
57x52
Fig. 9—AttachingShoeReturnSpring to SpringLink
Fig. 10—AttachingShoeReturnSpring to SpringLink
(RearWheel)
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8
DODGESERVICEMANUAL
57x54
Fig. 11—RemovingBrakeSupportPlates
andWheelCylinders(FrontWheel)
SEALING
COMPOUND
57x55
Fig. 12—RemovingWheelCylinderMountingBolt
(FrontWheel)
DUSTSEALS
57x56
Fig. 13—RemovingSupportPlatefromDustShield
(FrontWheel)
(7)Adjustthebrakes,asdescribedinParagraph11
ofthisSection.
5.REMOVINGTHESUPPORTPLATES
ANDWHEELCYLINDERS
Shoulditbecomenecessarytoremovethesupportplates
andwheelcylindersduetodamageorwear,proceedas
follows:
Removing the Front Support Plates
and Wheel Cylinders
(1)Removethewheelandtire,thenthebrakedrum.
(2)Removethefourretainingnutsthatattachthe
centerplanesupportplatesanddustshieldtothesteer-
ingknuckle.
(3)Disconnecttheflexiblebrakehosefromtheframe
bracket.
(4)Removethefourboltsthatholdthebrakeassembly
tothesteeringknuckle.(RefertoFigure11and
notethelocationandsizeofbolts.Threedif-
ferentlengthsareused.)
(5)Removethebrakeassembly(withdustshield),as
showninFigure11.Donotallowthedustshield
tostrikethebearingsurfaceofknuckleas
damagemayresult.
(6)RemovethebrakeshoesasdescribedinPara-
graph1.
(7)Removetheconnectingtubebetweenthewheel
cylinders.Donotdistorttube.
(8)Removeeachwheelcylindermountingboltafter
removingsealer(ifpresent),asshowninFigure12.
Now,removethesupportplateassemblyfromthedust
shield,asshowninFigure13.
(9)Removethewheelcylinders.Ifitisnecessaryto
servicethewheelcylinders,refertoParagraph7,Serv-
icingTheWheelCylinders.
Removing the Rear Support Plates
and Wheel Cylinders
Shoulditbecomenecessarytoremovethesupportplates
andwheelcylindersduetodamageorwear,proceedas
follows:
(1)Removetherearbrakeshoes,asdescribedinPara-
graph1,steps1 through5.
(2)Disconnectthebraketubeatthewheelcylinder.
Removethenutsandlockwashersthatholdthesupport
platesandwheelcylinderstothedustshieldandaxle
flange.
(3)Slidethesupportplatesoutandawayfromthe
axle, asshowninFigure14.Whenremovingthedust
shield,itisadvisabletoinstallthesealprotectorC-745,
thenslidedustshieldandsealoffaxle.
(4)Removetheboltsthatholdthewheelcylinderto
thesupportplates.Liftwheelcylinderawayfromthe
plates. Inspectandcleanthesupportplatesasdescribed
below.Ifreconditioningthewheelcylinders,referto
Paragraph7,ServicingtheWheelCylinders.
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BRAKES-SERVICE
57x57
Fig. 14—RemovingSupportPlates and
WheelCylinder(RearWheel)
6.INSPECTING THE SUPPORTPLATES
Clean the supportplates ina suitablesolvent,thenblow
drywithcompressedair,theninspect as follows:Check
thefreeness ofthe adjustingcams and returnspring
links. The adjustingcamsshouldturnwithoutbinding.
Check the condition ofthe adjusting cam dustwashers.
If the washers are cracked or deteriorated, new ones
should be installed at assembly. Ifany visualdistortion
of the supportplates is apparent, new platesshould be
installed.Thesupportplatesmust be flat and true.Coat
thecontactsurfaces ofthe cams and anchorswithlubri-
plate at reassembly.
7.SERVICING THE WHEELCYLINDERS
Wheelcylinderpistonsthat are badlyscored orcor-
BLEEDERSCREW
PISTON CUPJ^ EXPANDER
PISTONSPRING
PUSH ROD
CYLINDER
RETURNSPRING
CUPEXPANDER
PISTON CUP
PUSH ROD
CYLINDERBOOTPISTON
56x48
56x69
Fig. 15—FrontWheelBrakeCylinder(SectionalView)
Fig. 16—RearWheelBrakeCylinder(SectionalView)
rodedshould be replaced. Theold pistoncupsshould
bediscardedwhenreconditioningthehydraulicsystem.
Cylinderwallsthathavelightscratches,orshowsigns
ofcorrosion, can usually be cleaned up withcrocus
cloth,using a circularmotion.However,cylindersthat
havedeepscratches or scoring maybe honed,using
ToolC-3080,providing the diameter ofthe cylinderbore
isnotincreasedmorethan .002 inch.Acylinderthatdoes
notclean upat .002inchshould be discarded anda new
cylinderinstalled.(Blackstains onthe cylinderwalls
arecaused bythe pistoncups and will dono harm.)
Beforeassembling the pistons andnew cups inthe
wheelcylinder, dip them in superbrakefluid.Refer to
Figures 15or16 thenassemble the brakecylinders. If
theboots are deteriorated, ordonotfit tightly onthe
brakeshoe pin,as well asthe wheelcylindercasting,
newbootsshould be installed.
8.INSTALLING THE SUPPORTPLATES
ANDWHEELCYLINDERS
Installing the Front Support Plates
and Wheel Cylinders
(1)Installthebrakecylindersonthesupportplates,
thenpositionthesupportplatesonthedustshield.(Be
surethedustwashersareinplace.(SeeFigure13.)Now,
installthewheelcylinderattachingboltsandtighten
withthefingersuntilsnug.
(2)Lubricatethebrakeshoesaspreviouslydescribed,
thenslideintothesupportplates.
(3)Installthefourcoilspringendsintheholein
theshoewebsatthetable.Usingthetaperedendof
ToolC-3462,insertedthroughthespringandlink,slide
theendofspringintolink.(RefertoFigure9.)
(4)Installthebrakeshoeguidesandretainersafter
lubricatingthecontactareaofguidewithlubriplate.
(5)Installthewheelcylinderconnectingtube,being
carefulnottobendordistort.
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10DODGESERVICEMANUAL
(6)Slide the brakeassembliesover the steering
knuckles.Installbolts,nutsandtightento 55 footpounds.
Now,tighten the wheelcylinderattachingbolts to35
footpounds.
(7)Turn the brakeadjustingcams tothe fully re-
leasedposition.Attach the brakehose tothe frame
bracket.
(8)Install the drum and wheelassembly,thenadjust
thefrontwheelbearing, as described in Paragraph 5 of
theFrontSuspensionSection.
(9)Bleed and adjust the brakes as outlined in Para-
graphs 9 and 11 of thisSection.
installing the Rear Support Plates
and Wheel Cylinders
(1)Placethewheelcylinderonthesupportplate,then
installtheattachingbolts.Tightenbolts to35 footpounds.
(2)Lubricate the "ear" of theinnersupportplatewith
lubriplate,thenslidebrakeshoesintopositionbetween
thesupportplates.
(3)Install the fivecoilspringends inthe loop in
theshoetable.Using the tapered endof ToolC-3462,
insertedthrough the spring and link,slide theendof
springinto the link.(Refer to Figure 10.)
(4)Install the brakeshoeguides and retainersafter
lubricatingthecontactarea of theguidewithlubriplate.
Besure the positioning lipofthe guideslides
into the hole in the supportplate.
(5)Install a new seal inthe dustshield (if needed),
theninstallsealprotectorC-745intoseal.Installdust
shield and sealoveraxleshaft and downagainstflange.
(6)Slide the brakes and supportassemblyoveraxle
shaft and downagainstdustshield,makingsurethedust
washers are positionedaroundadjustingcams.
(7)Install the lockwashers and nuts.Tighten the nuts
to 55 footpounds.
(8)Turnthebrakeadjustingcamstothefullyreleased
position,thenattachthebrakehosetothewheelcylinder.
RemoveToolC-745sealprotector.
(9)Insert keyon slot in axleshaft,theninstalldrum.
Installwheel and tire,thenbleed and adjust the brakes,
asdescribed in Paragraphs 9 and11 of thissection.
9. BLEEDING THE BRAKESYSTEM
Cleaning all dirt off, and fromaround the mastercylin-
derreservoircover and from the bottom of the power
brakecylinder (ifso equipped), so thatdirt or gritwill
notdropinto the reservoirwhencover is removed.
Automaticrefiller,ToolC-837B(withadaptorC-3494A)
provides a convenient way for keeping the master cyl-
inderfilledwhilebleeding the brakesystem. Oneman
bleedertankC-3496withadaptorC-3494A
mayalsobeused.Followthemanufacturers
operatinginstructions.
Back off the adjustingcams tothe fullyreleasedposi-
tion.Thisallows the pistons in the wheelcylinders to
moveback, and permitsgreatermovement ofthe piston
whichwillexpel the air faster.
Startingwith the right rearwheelcylinder,wipe the
dirt offthe bleedervalve and attachbleederhose,C-650
to the valve.Place the other endofthe hose in a jar half
full of brakefluid.Thisistoprevent air frombeingdrawn
into the systemwhen the brakepedal is released.
Pumpbrakefluid by pushing the brakepedaldown
and let it returnslowly, to avoid air beingdrawninto
thesystem.Bleedintermittently,opening and closing
thevalveabouteveryfourseconds.Thiscauses a whirl-
ingaction inthe cylinderwhichhelpsexpel theair.
Continuethisoperationuntilbrakefluidruns out of the
bleederhose in a solidstream,without anyair bubbles.
Continuebleeding by repeatingthisoperation on the
leftrearwheel, the rightfrontwheel and finally the
leftfrontwheel.(Whenbleeding the frontwheelcylin-
ders, bleed the lowercylinderfirst so as to force allair
out of the connectingline.)
Ifnecessary,repeat the bleedingoperation if there
is an indication ofair remaining inthe system. Be sure
toreadjustthecamsafterthebleedingopera-
tion.
10. TEST FOR FLUIDCONTAMINATION
Inorder to determine if contaminationexists inthe
brakefluid, as indicated by swollen,deterioratedrubber
cups the followingsimpletests canbe made.
(1)Place a smallamount of drainedbrakefluid ina
smallclearglassbottle.Separation ofthe fluidinto two
distinctlayerswillindicatemineral oil content.
(2) Add water tothe contents and shake. Ifthecon-
tentsbecomemilky, oilis present. Ifthe contents re-
mainclear, itisnot contaminatedwithmineraloil. Be
safeanddiscardoldbrakefluidthathasbeen
bledfromthesystem.Fluiddrainedfromthe
bleedingoperationmaycontaindirtparticles
orothercontaminationandshouldnotbe
reused.
11. ADJUSTING THE BRAKES
Allcams (¾6 inch hex. head)operateagainst thetoe
end of the shoe weband extendthrough the brakedust
shield.
Since all fourshoes inthe frontwheelbrakes andthe
twoforwardshoes in the rearwheelbrakes are self
energizedwhen thecaris movingforward;theseshoes
areadjusted in one mannerwhile the remaining two
shoes inthe rearwheels are adjusteddifferently, as
shown in Figure 17.
Wheneverthebrakeshavebeenrelinedor
newshoeshavebeeninstalled,alwaysapply
pedalpriortoadjustingthebrakes.Thisac-
tioncausesthebrakeshoestocenterthem-
selvesinthebrakedrumandtoassistinthe
adjustment.
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BRAKES-SERVICE
11
i
LEFTFRONTRIGHTFRONT
RIGHTREAR
55X708
Fig. 17—BrakeAdjustingDiagram
Front Brake Adjustment
Turneachadjustingcamonbothfrontwheelsinthe
directionofforwardrotation,untiltheshoeliningis
solidagainstthedrum,(asshowninFigure17)and
wheelislocked.Turntheadjustingcamslowlyinthe
oppositedirection(eachcama littleata time)untilno
dragisfelt.
Rear Brake Adjustment
Theforwardrearwheelbrakeshoeadjustingcamis
rotatedinthedirectionofforwardwheelrotation.The
rearwardrearbrakeshoeadjustingcamisrotatedin
thedirectionofrearwheeltravel,asshowninFigure17.
12. SERVICING THE MASTERCYLINDER
Shoulditbecomenecessarytoremovethemastercylin-
derforrepairoroverhaul,refertoFigure18,thenpro-
ceedasfollows:
(1)Removethepedalreturnspring.
(2)Disconnectthepushrod.
(3)Disconnectthebraketubeatthemastercylinder.
(4)Disconnectthestoplightswitchleads.
(5)Removethenutsandboltsthatattachthemaster
cylindertothedashpanel.Slidemastercylinderstraight
outandawayfromdashpanel.
Cleantheoutsideofthemastercylinderthoroughly,
thenremovereservoirfillerpluganddrainallbrake
fluid. RefertoFigure 18 anddisassemblemastercylinder
forinspection.
Ifmastercylinderpistonisbadlyscoredorcorroded,
replacewitha newone.Pistoncupsandvalveassem-
blyshouldbereplacedwhenreconditioningmaster
cylinder.
Mastercylinderwallsthathavelightscratchesor
showsignsofcorrosion,canusuallybecleanedup
withcrocuscloth.However,cylindersthathavedeep
scratchesorscoringmaybehoned,providingthe
diameterofthecylinderboreisnotincreasedmore
than.002inch.A mastercylinderborethatdoesnot
cleanupat.002inchshouldbediscardedanda new
cylinderused.(Blackstainsonthecylinderwallare
causedbythepistoncupsandwilldonoharm.)Use
BOLT-
ROD
VALVE
NUT
END
T
SCREW
Fig. 18—MasterCylinder(ExplodedView)
55x81 A
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12
DODGESERVICEMANUAL
BOLTBAFFLE
GASKET
BODY
OUTLETPORT
PISTON
WASHER57x145
Fig. 19—MasterCylinder(DimensionReference)
extremecareincleaningmastercylinder
afterreconditioning.Removealldustorgrit
byflushingthecylinderwithalcohol;wipe
drywitha cleanlintlessclothandcleana
secondtimewithalcohol.Drymastercylin-
derwithairpressure,thenflushwithclean
brakefluid.(Besurethereliefportinthe
mastercylinderisopen.)
Beforeassembling,thepiston,cupsandvalveassem-
blyshould be dipped in newsuperbrakefluid.(Refer
toFigure 19for mastercylinderassemblydimension
specifications.)
13.SERVICINGHANDBRAKE
(ExternalType)
Removal and Installation
(1)Removeadjustingbolt, nutand guidebolt, ad-
justingboltnuts(3and1,Figure20).
(2)Removeanchoradjustingscrew.Pullband^as-
semblyawayfromtransmissionandoffpropellershaft.
1
GUIDEBOLT
lADJUSTING NUT
(LOWERCLEARANCE)
3ADJUSTING NUT
(UPPERCLEARANCE)
_^_ NUT
45 x 438
Fig. 20—ExternalContractingHandBrake
Relining Hand Brake Band (Band Removed)
Whenband is removed,proceed as follows:
(1)Removeoldlining.
(2) Cutthe newlining ¼ inchlongerthan there-
quiredlengthsothattherewillbe a slightbulge at the
centerwhen itis firstinstalled in theband.
(3)Drill and counter-borefourrivetholes(two at
eachend of thelining)tocoincidewiththeholes at the
extremeends of theband.Thesecounter-boresshould
be at leastone-halfthethickness of thelining.
(4)Rivet the twoextremeends ofthe lining tothe
respectiveextremeends of theband.Duetothe ¼ inch
excesslength,theliningwillnowbulgeslightly at the
centeroftheband.Snapthislininginagcinsttheband
tomake an eventight fit.
(5)Install the remainingrivets,startingfromeach
end and workingalternatelytoward the center.
(6)End-chamferthetwoopenends ofthe lining to
reducenoiseandgrabbingeffect.Reinstallbrakeband
inreversedisassemblyprocedure.
14.ADJUSTINGHANDBRAKE
(ExternalType)
(1)Sethandbrakelever in fullyreleasedposition.
Beforeadjustingbrake,besurethatfreeplay
(betweentheanchorbracket on thecenter of
thebandandthesides of thehandbrakesup-
port)does not exceed .005 inch.Otherwise,
banddistortionmayresultuponapplication
ofthebrake.Thisfreeplay, if excessive,may
bereducedbycompressingtheanchorbrack-
etin a viseortapping it gentlywith a hammer
against a blockoranvil.
(2)Removelockwire.Usingfeelergauge,adjust
anchorscrew(2,Figure20) so thatclearancebetween
band and drum at anchor is .015 to .020inch.Lock
anchorscrewsecurely.
(3)Adjustment of theguidebolt (1, Figure20)should
besuchthatbothupperandlowerhalf of bandhas a
likeamount of clearance. The guideboltmoves the
lowerhalf of band upto keep the upperhalf ofthe
bandfromdraggingandcausingprematurewear.Ad-
justingboltnut(3,Figure20)controlstheupperhalfof
theband.
(4)Turnadjustingboltnut(3,Figure20),untilthere
isjust a slightdragonthedrum,withupperandlower
halfhavinganequalamount of clearance.Thelock-
wire, whichretainstheanchorbolt,mustnot
bedrawnuptight.Thisrestrictionwillcause
unevenwearanda poorbrake.
15.ADJUSTINGHANDBRAKECABLE
(ExternalType)
Sometimes,afterlongservice,thecablewillstretch to
suchanextentthatpullingbackonthehandbrakelever
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BRAKES-HAND13
BRAKESHOEANCHORPIN
OUTPUTSHAFTREARBEARING
OILSEAL
BRAKESUPPORT
GREASESHIELD
BRAKESHOEASSEMBLY
BRAKESUPPORT
CABLEGUIDECLAMP
BRACKETASSEMBLY
BRAKEANCHORWASHER
BRAKEANCHORSHOEGUIDE
BRAKESHOEOPERATING
LEVERLINK
BRAKESUPPORTGREASE
SHIELDSPRING
BRAKESHOE
RETURNSPRING
BRAKESHOEADJUSTINGSLEEVE
BRAKESHOEADJUSTINGNUT
Fig. 21—InternalExpandingHandBrake
¯¯`—BRAKESHØEADJUSTINGSCREW
53x58
BRAKEANCHORSHOEGUIDE
BRAKEANCHORWASHER
BRAKESUPPORTGREASE SHIELD
BRAKESHOEOPERATINGLEVERLINK
4r
BRAKESHOEANCHOR
BRAKESHOEANCHOR
BRAKESUPPORT
BRAKESHOE& LININGASSY
SHAFTFLANGE& BRAKEDRUMASSY
BRAKESUPPORT
SPACERSLEEVE
SHAFTFLANGEWASHER
SHAFTFLANGENUT
BRAKESUPPORTGREASESHIELDSPRING
BRAKESHOERETURNSPRING
BRAKEADJUSTING
SCREWCOVER
BRAKEADJUSTING
SCREWCOVER
SCREW
BRAKESHOEOPERATINGLEVERSCREW
BRAKESHOEOPERATINGLEVER
BRAKESHOEOPERATINGLEVERSCREWLOCKWASHER
BRAKESHOEOPERATINGLEVERSCREWNUT
BRAKESHOEADJUSTINGSCREW
BRAKESHOEADJUSTINGNUT
BRAKESHOEADJUSTINGSLEEVE53x3A
Fig. 22—InternalExpandingHandBrake(ExplodedView)
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14DODGESERVICEMANUAL
OPERATI
LEVER.CONTROLCABLE
GUIDECLAMP
CLAMPBOLT,
NUT AND
LQCK
WASHER
CABLE
ADJUSTING
NUT
tea*
CONTROLCABLE^
CABLESPRING
SHOEADJUSTINGSCREW, NUTAND SLEEVE
BALL ENDOF CONTROLCABLE50x137 A
Fîg. 23—RearView of InternalExpandingBrake
willnotapplybandtodrum.Loosenlocknut(4,Figure
20), removeclevispinfromyokeandturnyokeuntil
cableslackistakenup.Makecertainthatlocknutis
tightenedafterassembly.(Thisisnota substitutefor
handbrakeadjustment.)
16. SERVICINGHANDBRAKE
(InternalType)
ThehandbrakeshowninFigure21,istheinternalex-
pandingtypeandisusedonlyoncarsequippedwith
PowerFliteorTorqueFliteTransmissions.
Thebrakeisfullyenclosedtokeepoutdirtandoil
andrequiresverylittleservicing.Longerlininglifeis
assuredbyprotectionagainstdirtandtheuseofCycle-
bondlinings.Theadjustments,whenneeded,arevery
simpleforboththesteelcontrolcableandtheshoes.
Disassembly
Toservicetheinternalexpandinghandbrake,referto
Figures21and22,thenproceedasfollows:
(1)Disconnectthepropellershaftatthetransmis-
sion.
(2)EngageholdingToolC-3281withthecompanion
flange,thenloosenandremovethecompanionflange
nut,lockwasherandflatwasher.
(3)InstallPullerToolC-452onthecompanionflange;
removingflangeandbrakedrum.
(4)Disengagetheballendofcablefromtheoperating
lever.
(5)Separateshoesatthebottom,allowingthebrake
shoeadjustingnut,screwandsleevetodropout,then
releasetheshoes.
(6)Prythebrakeshoereturnspringupandoverthe
righthandbrakeshoepin,thenworkthespringoutof
theassembly.
(7)Pryoutthebrakeshoeretainingwasherandre-
moveouterguide.
(8)Slideeachshoeoutfromundertheguidespring.
(Astheshoesareremoved,theoperatingleverstrut
willdropoutofplace.)
(9)Sepraratetheoperatingleverfromtherighthand
brakeshoe,byremovingnut,lockwasherandbolt.
Thebrakenowhasbeendisassembledasfarasnec-
essaryforreplacementofwornordamagedparts.
Assembly
(1)Assembletheoperatinglevertotherighthand
brakeshoe.
(2)Slidetherightandlefthandbrakeshoesunder
theguidespringandupontopoftheinneranchorguide.
(3)Spreadtheshoesandinserttheoperatinglever
strutwiththewideslottowardtheoperatinglever,and
thestamped"top"facingup.
(4)Worktheshoereturnspringunderthegrease
shieldspringandsecureendsinproperholesinwebs
ofshoes,asshowninFigure21.
(5)Spreadthebottomofbothshoesapartandinstall
thebrakeshoeadjustingnutscrewandsleeve.Besure
toinstalltheadjustingnut,screwandsleeve
intheproperposition,asshowninFigure21.
Ifinstalledinthereverseposition,adjustment
wouldbedifficult.
(6)Placetheouteranchorguideovertheanchor,then
secureshoeswithretainingwasher.
(7)Turnthebrakeshoeadjustingnutuntiltheshoes
areina releasedposition,theninstallthebrakedrum.
Besurethebrakeshoesarecenteredonthe
backingplateandarefreetomove.
(8)Adjustthebrakeshoesandcontrolcableasout-
linedbelow.
Adjustment
(1)Removeadjustingscrewcoverplate.
(2)Turnthebrakeshoeadjustingnut,asshownin
Figure23todecreaseshoe-to-drumclearanceuntila
slightdragisfeltonthedrum.Backoffadjustingnut
atleastonefullnotch(usingSpannerWrenchC-3014)
oruntilbrakedrumisfree.Besurethetworaised
shouldersontheadjustingnutareseatedin
thegroovesontheadjustingsleeve.
(3)Testthehandbrakeleverfortravel.Whenprop-
erlyadjusted,thereshouldbefroml½to2 inchesof
handbrakeleverrodtravel.Neversubstitutefor
abrakeshoeadjustmentbyadjustingcable.
(4)Installtheadjustingscrewcoverplate.
17. SERVICINGHANDBRAKECABLE
(InternalType)
Removal
Ifremovalofthecontrolcableisrequiredforreplace-
mentorrepair,proceedasfollows:
(1)Loosentheguideclampingbolt,asshowninFigure
23, thenremoveadjustingscrewcoverplate.
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BRAKES-POWER
15
i
(2) Prythe ball endofthe cable upandoutofthe
operatingleverslotwith a screwdriver.
(3)Remove the controlcablefrom the guide.
Installation
(1)Slidecableinto the guide,theninsertToolC-3015
between the springretainerwasher andthe ball onthe
end of cable.
(2)Hook the cableintotheslot in theoperatinglever,
with the leverbetween the ball andthe washer, as
showninFigure23.Thecablemustbeinstalled
sothatthecableconduitisnotpulledtaut
betweenanyofthefasteningpoints.Nokinks
shouldbeallowedintheconduitatanypoint
andallbendsintheconduitmustbeofa radius
ofnotlessthan6 inches.Theconduitmustnot
hangbelowtheleveloftheframebetweenthe
frameclipandthecableguideclamp.
Adjustment
After the installation has beencompleted,adjust the
cable as describedbelow.
Alwaysbesurethatthehandbrakelever
handleisinthefullreturnedpositionbefore
thecablelengthadjustmentismade.With
adjustmentmadeasdescribed,thehandbrake
shouldnotdragnorchatter.
Withthebrakeshoesadjustedproperly
therewillbea freeplayinthebrakeoper-
atinglever. The handbrakecableadjusting nut
should be positionedagainst the cableguide so that the
brakeoperatinglever is centered inits normalfreeplay
arc. To lockthisadjustment,tighten the cableguide
clampsecurely and thentighten the handbrakecable
lock nut against the adjusting nut.The cableadjusting
nutshould be held in positionduringthisoperation so
that the cablelengthadjustment isnot disturbed.
18. CYCLEBONDBRAKELINING
Pre-cementedcyclebondbrakelining canbe success-
fullybonded to either newor usedshoes,providing cer-
tainprovensteps are followed. See instructions con-
tained in shopreplacementpackages.
POWERBRAKESCONTENTS
SERVICEINFORMATION
AdjustingPedalLinkage
Cleaning
GeneralInformation
Inspection
InstallingthePowerBrake in Vehicle
PowerBrakeAdjustment 9
PowerBrakeOperation 1
RemovingthePowerBrakefromVehicle
Servicing the PowerBrake
Testing the PowerBrake (Onthe Bench)
Testing the PowerBrake(On the Vehicle)
SERVICEDIAGNOSIS
Par.
10
5
—
6
8
9
1
3
4
7
2
Page
26
22
16
22
25
25
16
19
19
24
18
CONDITIONS
POSSIBLECAUSES
Leakage in internalhoseconnectionto end plate or pistontube
Leakage at balancingdiaphragm
Leakage at poppetdiaphragm
Leakage at rubberseat of poppetassembly
Vacuum
Leak
(Unitin
Released
Position—Drop
in
Vacuum
Gauge
Readingin
Excess
of
¼
Inch
in
60
seconds).
•
•
•
•
Vacuum
Leak
(UnitinApplied
Position—Drop
in
Vacuum
Gauge
Reading
in
Excess
of
1
Inch
in
10seconds).
•
•
•
•
Rough
Engine
Idle
Delay
In
Power
Unit
Assist
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16DODGESERVICEMANUAL
SERVICEDIAGNOSIS-(Continued)
CONDITIONS
POSSIBLECAUSES
Scoredatmosphericseat at center of pistonplate
Leakage at valverodseal
Leak at pistonpacking
Leakatmountingringoratpistonrodseal
Vacuumleaksatreservetankhoseconnections
Weakorbrokenvalveactuatingspring
Weakorbrokenpedalreturnspring
Vacuum
Leak
(Unit
in
Released
Position—Drop
in
Vacuum
Gauge
Reading
in
Excess
of¼
Inch
in
60
seconds).
Vacuum
Leak
(Unit
in
Applied
Position—Drop
in
Vacuum
Gauge
Reading
in
Excess
of1
Inch
in
10
seconds).
•
•
•
•
Rough
Engine
Idle
•
Delay
In
PowerUnits
Assist
•
•
SERVICEINFORMATION
PROCEDURES
GENERALINFORMATION
Fororientationpurposes,thepistonrodendof
thepowerbrakeunitwillbereferredtoasthe
"forward"endoftheunitandtheaircleaner
endwillbedesignatedasthe"rear"ofthe
unit.
ThepowerbrakeunitshowninFigure1,is a vacuum
powerbrake,designed for usewith a mastercylinder
andpedallinkage ofthe reactionarytype. A tubeex-
tendingfromtheaircleaner at therear, is connected to
theintakemanifoldthrough a hose, a vacuumreservoir
and a checkvalve.(SeeFigure 2.)
Thepowerbrakeconsists of threebasiccomponents,
namely, an elipticalshapedpowercylinder, a vacuum
CYLINDER -
VACUUMINSPECTION
PORT
YOKE
VACUUMTUBE
CONNECTION
57x181
Fig. 1—PowerBrakeAssembly
piston and rodassemblyand an internalpoppettype
controlvalve, as shown in Figure 3.
Thecontrolvalveoperating rod moveswithin the
pistonrodandactuatesthevacuumvalveandpoppet.
Theatmosphericvalveseatis a part of thepistonplate.
Theaircleanerislocatedattherearendoftheunit and
connectsdirectlyintothecylinderattherearsideofthe
piston.Whenin a releasedposition,theforward,orpis-
tonrodend of theunit is open to atmosphere,through
theatmosphericvalveportandopentovacuum(through
thevacuumvalveport)when inthe appliedposition.
Withbothsides ofthe pistonopen to atmospheric
pressure,when inthe releasedposition, the unit is
referredto as being"atmospheric"suspended.
1. POWERBRAKEOPERATION
With the enginerunning andthe brakepedal inthe
releasedposition, the ramp atthe upper endofthe
triggerarmrestsagainsttheend of thevalveoperating
rodwithsufficientforce to compress the valvereturn
springandholdthevalve inthe releasedposition, as
showninFigure4.Inthereleasedposition,thevacuum
portisclosedandtheatmosphericport of thevalve is
open to admit airtothe frontside ofthe piston. The
vacuumpistonreturnspringholdsthepistoninthefully
releasedposition.
As the brakepedal is depiessed, the trigger arm
movesback,releasingsufficientpressureagainst the
valveoperatingrod, to permit the valvereturnspring
toclosetheatmosphericport,andopenthevacuum
portofthecontrolvalve.Asthefrontchamberoftheunit
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BRAKES-POWER17•
REACTIONARYLINKAGE
DASHPANEL
INTERNAL VALVEPOWER
TO ENGINECYLINDER ASSEMBLY
INTAKE MANIFOLD
VACUUM
CHECK
VALVE
J
üMASTERrfS
`CYLINDER—Hl«
^-VACUUM RESERVOIR
HYDRAULICTUBE TO
57×U5 WHEELCYLINDERS
Fig. 2—PowerBrakeSystem
assumesa stateofvacuum,thepistonmovesforward
andappliespowertotheupperendofthepowerlever.
Poweristhentransmittedtothemastercylinderthrough
thereactionarylinkageandthemastercylinderpush
rod,asshowninFigure5.Sincethevalveandrod
mechanismarehousedwithinthepistonandpistonrod
assembly,anymovementofthepistonandrodresults
ina likemovementofthevalverod.Anymovementof
thevalverodforward,increasesthepressureagainst
therampattheupperendofthetriggerarm,toclose
thevacuumportofthecontrolvalve,andarrestany
furtherincreaseinbrakeapplication.Toincreasebrake
application,itisnecessarytoincreasethepressure
againstthebrakepedal,whichpermitsthevalvereturn
springtoreopenthevacuumportandincreasethe
vacuuminthefrontchamberoftheunit.
Whenthedesireddegreeofbrakeapplicationis
57x178
Fig. 4—PowerBrake(ReleasedPosition)
reached,andthedriverholdsa givenpressureagainst
thebrakepedal,nofurtherincreaseinpowerapplica-
tionwilltakeplace.Withthebrakepedalheldata
givenpressure,thepistonandrodwillmoveonlytothe
pointwheretheloadonthevalverodisincreasedby
theramponthetriggerarmsufficienttoclosethe
vacuumport,asshowninFigure 6. Thepointwhereboth
thevacuumandatmosphericportsareclosed,isre-
ferredtoasthe"holdingposition."Withthecontrol
valveinthe"holdingposition,"anydegreeofbrake
applicationwillbeheld.Assoonasthepressureagainst
VACUUMHOSE
VACUUMTUBE / VALVEVACUUM
PASSAGE
VACUUM
CHAMBERRETURN
SPRING
GASKET
SPRING
SEAL
VALVE ROD
RETURN SPRING
YOKE
AIR
CLEANER
ATMOSPHERIC
CHAMBER
ATMOSPHERIC VALVE
(PORT CLOSED)
VACUUM
VALVE
(PORTOPEN)
PISTON ROD
VALVE OPERATING
ROD
APPLIED
DIRECTION57x176
Fig. 3—PowerBrake(SectionalView)
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18DODGESERVICEMANUAL
Fig.
57x179
-PowerBrake(AppliedPosition)
thebrakepedal is released,sufficiently to reopen the
atmosphericport, a balance of pressure is established
on bothsides of the vacuumpiston. The vacuumpiston
returnspring isnow free to return the piston tothe fully-
releasedposition and release the brakes.
Operation of the Reactionary Linkage
With the brakepedal inthe releasedposition, the pedal
returnspringholds the valvetrigger pin against the
forward endofthe slot inthe powerlever.(Refer to
Figure 4.) In thisposition,sufficientpressure is applied
by the ramp at the upper endofthe triggerarm, to hold
thevalveoperating rod in the releasedposition.When
pressure is applied tothe brakepedal, the trigger arm
pinmoves to the oppositeside of the slot in the power
lever, as shown in Figure 5,to reduce the forceagainst
the end of the valveoperating rod sufficiently to permit
thevalvereturnspring to close the atmosphericport,
andopen the vacuumport,thusconnecting thefor-
wardside ofthe vacuumpiston to intakemanifold
vacuum to apply the brakes. Asthe pistonbegins to
move, the force of the piston is transmittedthrough the
piston rodand lever pin, to the lever (the greaterpart
ofthisforcebeingtransmittedthrough the powerlever
to the mastercylinderpushrod).During any degree of
braking, a smallpercent of the powerdeveloped bythe
unit,reactsbackthrough the pedallinkage to oppose
thepressureapplied bythe driver,thusassuring the
driver of "pedalfeel," as well as positioncontrol.Since
thepiston rod tends to overtravel the valverod, thecon-
trolvalveautomaticallyreturns toits mid position; a
positionwhereboth the vacuum and atmosphericports
areclosed. In thisposition, the trigger armpinis at the
midposition inthe slot ofthe powerlever andany
57x180
F¡g. ¿—PowerBrake(HoldingPosition)
degree of brakingthat was attained,will be held.This
position is referred to as the "holdingposition." In this
position, the powerunitforces andthe forcesapplied
to the brakepedal are in balance.
2. TESTING THE POWERBRAKE
(On the Vehicle)
Totest the powersystem for operation onthe vehicle
withvacuum,proceed as follows:
(1)Remove the screwplugfrom the mountingring
andconnect the testfitting,hose and vacuumgauge
atthisport.
(2)With the brakes inthe releasedposition,start the
engine and allow to idle,whileobserving the vacuum
gauge. (A zeroreadingindicatesthat the powerunit
isfullyreleased.) A vacuumgaugereading ofoneto
16inches or moreindicatesthat the powerunit isnot
releasingproperlywhich maybedueto faultypedal
adjustment or faultypowerunitoperation.
(3)Depress the brakepedalslowly and observe the
vacuumgaugereading. (A vacuumgaugereading of
one to16 inches or more,dependinguponpressure
applied tothe pedal;indicatethat the powerunit is
operating.)
Azeroreading onthe gaugeindicatesfaultypower
unitoperation,restriction inthe vacuumsupplyline, or
thebrakepedalrequirescorrectiveservice.
(4)Failure of thepowerunit to functionproperlyindi-
catestheneedforcorrectiveservice.Beforeproceed-
ingwithanycorrectivemeasures,firstdeter-
mineifthesourceofvacuumissatisfactory.
If a vacuumgauge isnot available,proceed as
follows:
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BRAKES - POWER
(5)Depressthebrakepedalseveraltimes to deplete
anyvacuum in thesystemandreservoir.
(6)Depress and hold the pedalpartiallydepressed
whilestartingtheengine.Assoon as theenginestarts,
thepedalwillfallawayunder the pressureapplied.
(7)Shut off engine and then,depress the pedal
fromsix to tentimes.Thereshould bea noticeablein-
crease in theeffortrequiredtodepressthepedaltothe
samepoint the lasttimecompared tothe first, asthe
vacuuminthesystemisdepleted.
(8) If there isno noticeabledifference inthe pedal
effortwith or without the enginerunning,check fora
restriction in thevacuumsupplyhose, air cleaner, in-
correctpedaladjustmentorfaultypowerunitoperation.
(9)Disconnectthevacuumhosefromthepowerunit
andplace a fingerover endof hose. A highvacuum
indicatesthatvacuum is beingapplied tothe unit. If
novacuum is present at theend of thevacuumhose
whentheengineisrunning, a restrictioninthevacuum
supply is apparentandshould be corrected.
(10) If vacuum is beingsupplied tothe unit,check
thepedallinkageadjustment as described in Para-
graphs9 and10. If alladjustmentsaremadeaccording
totherecommendedprocedureandtheunitfailstofunc-
tionproperly,removetheunitfromthevehicleforcom-
pleteoverhaul.
3.REMOVING THE POWERBRAKE
FROMVEHICLE
Shouldtheabovetestsindicatetheneed foran over-
haul,removethepowerbrakeunitfromthevehicle as
follows:
(1)Insert a woodenblock or wedgebetween the
powerleverandthebracket.(The useofa wedge or
blockwillpreventdamage to theramp ofthe trigger
arm.)
(2)Scratchalignmentmarksacross the powerunit
adjacenttothevacuumtestport,andacrossthemount-
ingbracket.Thenbetween the mountingbracket and
thefirewall.
(3)Disconnectthevacuumhosefromtheend ofthe
powerunit.
(4)Remove the boltsthatattach the powerunit
mountingbrackettothefirewall.Slideunitandbracket
straightoutfromfirewalland outof enginecompart-
ment.Now,removepowerunitfrommountingbracket.
4.SERVICING THE POWERBRAKE
Todisassemblethepowerbrakeunitforrepair or over-
haul,refertoFigure7,thenproceed as follows:
Donotclamptheyokeoftheunitina viseor
allowthepistoncylindertobecomedented
duringthedisassemblyoperation.
(1)Place a scribemarkacrosstheflange of cylinder
andendplate,thenremovetheattachingnutsandbolts.
AIRCLEANER
CYLINDER
NUT (4)
BALANCING
PISTON
PACKING / PINS
PACKINGPLATE
WICKING
EXPANDERSPRING
RETAINERPLATE
SCREW (5)
VALVE
DIAPHRAGM
HOUSING
SCREW (4)i ¶ (5y^ar¾^^v¼iL·ir¾^^835' SNAP
NYLON
BUTTON
STOPWASHER
PISTON ROD
VALVE ROD
MOUNTINGRING
SPRING
SEAL
GASKET
BOLT (4)
ENDPLATE
57x177
F¡g. 7—Power Brake(ExplodedView)
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