Suburban 3/4 Ton 4WD V8-305 5.0L (1986)
Fig. 9 Installing input rod & piston assembly into booster
1.
Install O-ring onto spool plug, then push spool plug into housing and install retaining ring.
2.
Coat piston bore and piston seal with clean power steering fluid, then install seal into bore. Lip of seal must face away from the master cylinder
mounting flange. Also, ensure seal is fully seated in the housing.
3.
On 1980---84 models, proceed as follows:
a. Lubricate input rod end, input rod seals and seal installer with clean power steering fluid.
b. Slide seals on tool with the lip of the cups toward open end of tool, Fig. 8.
c. Slide tool over input rod end and down to the second groove, then slide the forward seal off tool into the groove.
d. Install remaining seal in first groove. Ensure seals are fully seated. On JD3 and JD5 models, only one seal is used.
4.
On all models, lubricate piston and piston installing tool, then hold large end of tool against the piston, Fig. 9.
5.
Slide the piston installing tool and piston into piston bore and through piston seal, then remove piston installing tool.
6.
Install hose fitting O-ring, if removed.
7.
If accumulator valve was removed, install new valve seat into valve bore. The seat can be forced to the bottom by installing the check valve
assembly, Fig. 7.
8.
Install new dump valve over check valve assembly. Ensure dump valve plunger is held in position until installation is complete.
Fig. 2 Removing Accumulator
9.
Install spool return spring and spool valve assembly into bore in housing. Extend power piston lever to accept sleeve on spool valve, then slide
lever pins into slot in sleeve.
10.
Install new housing seal in groove in hosing cover, then lubricate input rod seals.
11.
Install housing cover and cover attaching screws. Torque screws to 18---26 ft. lbs.
12.
Install output rod, spring, baffle and new spring retainer, then secure baffle and spring retainer using a suitable tool.
13.
Install accumulator seal and accumulator in housing, then place retaining ring over accumulator.
14.
Install tool No. J-26889 over accumulator, then using a suitable C-clamp, depress accumulator, Fig. 5, and install retaining ring.
15.
Remove C-clamp and tool No. J-26889, then check retaining ring for proper installation.
16.
Install mounting bracket and bracket attaching nut. Torque attaching nut to 110 ft. lbs. and lock in position.
17.
If repair kit contains a grommet retained pedal rod, proceed as follows:
a. Install boot on pedal rod, if equipped.
b. Install new grommet in groove near end of pedal rod.
c. Moisten grommet with water, then insert grommet end of pedal rod into the input rod end of the booster housing.
d. Push on end of pedal rod to seat grommet. When grommet is fully seated, pedal rod will rotate freely with no binding.
e. Slide open end of boot onto the hub of the booster.
18.
If repair kit contains a staked two piece pedal rod, proceed as follows:
