Removal & Installation: PUSHROD: Installation
- Install new pushrod grommet. From under the hood, position the front pushrod half in pushrod bracket assembly. DO NOT lubricate pushrod, pushrod grommet or booster cavity
- From under dash, thread the rear pushrod half onto the front and tighten. Position the pushrod on the pedal assembly and install foam washer and clevis pin.
- Position the hydraulic unit while guiding the front pushrod half so that it is started into the rear booster cavity. Install the hydraulic unit onto the pushrod mounting bracket. Tighten NEW mounting bolts to 37 Ft. Lbs. (50 Nm.)NOTE: The Bolts securing the hydraulic unit to the pushrod bracket must be replaced any time they become loose or are removed. Failure to replace the special prevailing torque bolts, which use an encapsulated thread locking compound may result in loosening of the hydraulic unit to pushrod bracket, which will cause reduced braking ability.
- Seat the pushrod and grommet in booster cavity by continuously applying a minimum of 75 Ft. Lbs., for no less than 5 seconds. Grommet seating is a two stage process. The pedal will feel hard as it is first applied, then pressure will fall away, finally the pedal will get hard again. When seating grommet always apply constant pressure.
- Inspect for proper pedal retention as described in Pushrod inspection. Position pump/motor assembly on hydraulic unit. Install mounting bolt and tighten to 10 Ft. Lbs. (13 Nm.) Install cross-car brace. Reconect electrical connections at hydraulic unit.
- Reconnect negative battery cable. Bleed brake system as described in this article. Adjust brake light and cruise control switches, as necessary.