| 13. Release the compression tool when the piston spring (27) will push out the washer followed by the output piston (25) the latter is then discarded.
14. Refitting is the reverse of the removal sequence but particular attention must be given to the following:—
(i) All seals must be renewed and lubricated with Girling Brake Fluid; lubricate the bores and pistons wlth Girling Red Rubber Grease.
(ii) Fit a new output piston (25) as the piston rod seal can only be fitted during manufacture and confirm that the taper seal has the larger diameter nearer the reduced end of the piston.
(iii) Fit the spring (27) to the output piston (25) feed into the bore spring first followed by the washer and hold in position with the compression tool and clip the tool under the mounting flange of the cast body (29).
(iv) Ensure that the circlip does not foul the side of the bore and fits snugly into its groove; this operation must be unhurried and the circlip pliers must be secure on the circlip for any damage to the bore can result in brake failure. Remove the compression tool from the cast body.
(v) Fit the nylon spacer (25) into the bore large end first followed by the gland seal lip end first and finally fit the bearing bush (23).
(vi) Fit the control piston to the bore so the trans-verse hole aligns with the hole in the valve chest (26).
(vii) It is unlikely that the two nylon valves (22 and 31) will need renewing but when it is necessary their faces should be lapped on a piece of glass with a fine lapping paste to ensure they are airtlght.
Fit the valves (22 and 31) and Tee shaped lever (11) complete so the horseshoe spring location above the air valve (31) is away from the two securing screws inside the valve chest |
(26). It will be necessary to compress the end plug (8) to locate the end of the Tee shaped lever (11) in the control piston.
(viii) Fit a new rubber grommet in the flange of the vacuum cylinder (19) and locate a new gasket on the mounting face of the cast body (29).
(ix) Fit the vacuum cylinder (19) and clamping plate with the centre hole of the cylinder over the protruding bearing bush (23) and transfer pipe (17) ensuring there will be space over the grommet for the passage of air when the end cover (15) is fitted but leave the three bolts slack.
(x) Position the piston (5) and return spring (6) inside the vacuum cylinder (19) and push It down through the full stroke several times to align the bearlng bush (23); remove the piston (5) and return spring (6) and tighten the three cylinder attachment bolts taking care not to displace the vacuum cylinder (19) on the flange of the cast body (19). If the cylinder is displaced it can cause the brakes to hang-on .
(xi) Remove the sponge rubber backing ring (2) from the piston flange and fit the new one from the service kit. Smear the special lubricant supplied in the kit on the leather seal (3) of the piston (5).
(xii) Smear the piston rod (18) with Girling Red Rubber Grease and with the return spring in front offer up the assembly to the vacuum cylinder (19).
(xiii) Position the end cover (15) with a new gasket (1) on top of the piston (5) and press down taking care the piston rod (18) enters the bearing bush (23) without damage. DO NOT DISTURB THE SCREW AND LOCK NUT IN THE END COVER.
(xiv) Secure the end cover (15) with the nuts and screws |
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