Pushrod and Retainer

Figure 4 - Powermaster III Unit:

Figure 4

Remove or Disconnect

1. Depressurize Powermaster III Unit, refer to "Depressurizing the Powermaster III Unit" in this section.
2. Driver side sound insulator panel
3. Cruise control vacuum solenoid valve (if equipped).
4. Stoplamp switch from pushrod pedal pin, retainer and washers from brake pedal pin
5. Pushrod from Powermaster III Unit
^ Pull back on brake pedal
^ Considerable force will be required
6. Pushrod from brake pedal and Powermaster III Unit.
7. Retainer from pushrod
^ Discard old retainer

Inspect

^ Pushrod for deformation

Install or Connect

NOTICE: Before installing pushrod and retainer, make sure that control valve seat that mates with pushrod is clean and free of any of the old pushrod retainer.
1. Using dry compressed air, blow out any remaining portion of the old retainer from Powermaster III control valve seat.
2. New retainer to pushrod

NOTICE: Take care not to damage grommet when installing pushrod through grommet and into Powermaster III.

3. Pushrod through grommet and into Powermaster III Unit.
4. Lubricate pushrod pedal pin with lithium grease.
5. Eyelet of pushrod over pedal pin
6. Spring washer, flat washer, and retainer on pedal pin

^ Spring washer must be between flat washer and pushrod
7. Seat pushrod into Powermaster III

^ Push down on brake pedal until pedal is at the end of its travel
^ Considerable force may be required to engage retainer properly

Inspect

^ Pull back on brake pedal with moderate force to make sure that pushrod is fully seated.
8. Stoplamp switch and adjust refer to BRAKES (SECTION 5)
9. Cruise control vacuum solenoid, if removed, and adjust
10. Driver side sound insulator panel