Removal and Installation

POWERMASTER UNIT REMOVAL AND INSTALLATION

IMPORTANT: Refer to Technical Service Bulletins for the latest information.

IMPORTANT: Some components of the Powermaster system appear to be similar to the Antilock Braking System (ABS) but they are different. Powermaster System is not an antilock braking system.

WARNING: Failure to fully depressurize Powermaster unit before performing service operations could result in injury to service personnel and damage to painted surfaces.

Removing/Installing Powermaster Assembly:

REMOVAL:
1. Depressurize Powermaster by turning ignition off, applying and releasing brake pedal a minimum of 10 times using approximately 50 pounds force on the pedal.
2. Disconnect electrical connector (40) from pressure switch.
3. Disconnect electrical connector (41) from electro-hydraulic (E-H) pump.
4. Remove brake pipes (42) from Powermaster unit (44).
5. Remove two attaching nuts (43).
6. Remove pushrod (17) from brake pedal.
7. Remove Powermaster unit (44).

INSTALLATION:
1. Install Powermaster unit.
2. Install pushrod (17) to brake pedal.
3. Install attaching nuts (43) and torque to 30-45 Nm.m (22-30 lb. ft.).
4. Connect brake pipes (42) to Power Master unit (44) and torque nuts to 14-20 Nm.m (120-180 lb. in.).
5. Connect electrical connector (41) to E-H pump.
6. Connect electrical connector (40) to pressure switch.
7. Bleed hydraulic system. Refer to Brake Bleeding Service and Repair