fitting instructions

for

Remote Vacuum Servo Units Types 6 and 7

(For single line braking systems)

Issue 3 BTL046/3

"

A range of servo installation kits and servo units, with boost ratios to suit cars and light vans are detailed below. Specific applications and interchangeability with obsolete Girling versions are listed on page 6. For vehicles not listed, advice on models not shown. or Technical assistance on installation or overhaul, please contact AP Lockheed Service Technical Department.

Installation

kits and servos Remote servo technical data

Installation kit no.

LE15741 LE15370 NLA NLA NLA LE72696 NLA LE10117 NLA NLA NLA NLA NLA

Servo part no.

LR17792 LRl7793 LR17S12 LR17813 LR17814 LR1781B LR15248 LR1B221 LR1B230 LA1S503 LR1B504 LR17551 LR17552

Boost ratio
2.30:1 1.65:1 1.65:1 190:1 2.78:1 1.90:1 2.00:1 3.00:1 4.25:1 4.50:1 3.60:1 3.00:1 3.00:1

Slave cylinder bore

5/S"

Reaction piston bore

5116" 5/16" 5/16" 5/16' 3/8" 5/16" 5/16" 5/16" 318"

Service repair kits Major

LK11061 LK11067 LK11067 LK11073 LK11066 LKl1073 LK11058 LK11062 LKl1059 LK11034 LKll033 LK12548 LK1254B

Piston

Air valve
LK11032 LK11032 LK11032 LK11032 LK11032 LK11032 LK11032 LK11032 LK11032 lKl1011 LK11011 LK12551 LK12551

Ancillaries
LK16042 LK16042 LK16042 LK16042 LK16042 LK16042 LK16042 LK16042 LK16042 LK1S042 LK16042 LK16042 LK16042

7/S" 7/8"
11/16" 11/16" 11/16" 7/8" 5/8" 5/8" 5/a" 5/8" 518" 5/8"

9/16"
1/2' 1/2' 1/2"

LK12565 LK12565

NOTE: All necessary extra component parts are readily available In the ancilliary repair kit, excluding the In nne non-return valve which is obtainable separately under AP Lockheed part no. LV15069.

General fitting instructions

To ensure correct Installation of the AP lockheed remote vacuum servo unit, thoroughly read and adhere to the fitting instructions prior to carrying out any work on the vehicle. Introduction
The vacuum servo unit is incorporated into the hydraulic braking system, remote from the master cylinder, as an intermediate stage operating between the master cylinder and the brake assemblies. The two main parts of the servo unit consist of the vacuum servo mechanism and the hydraulic slave cylinder assembly. These component parts are bolted together so that the slave cylinder piston is in line with, and Is operated directly by, the servo push rod. A plastic non-return valve is fitted Into the vacuum shell and an integral air cleaner is incorporated loreign matter entering the air control valve chamber. to prevent

The servo unit is designed to give no assistance with very light brake application. In the absence of servo asslstanca due to loss of vacuum, an unrestricted passage for the fluid will exist. The brakes can still be applied, therefore, by the normal action of the pedal on the brake master cylinder, but this would demand heavier toot pressure to achieve the same degree 01 braking as with servo assistance. When this servo unit is used to replace a non AP Lockheed servo or is Installed on a vehicle previously without a servo, the following Installation recommendations must be observed. Note: Not for use on vehicles with tandem or dual line braking systems except for specific applications where twin servo units are fitted_ In this Instance, units must be replaced in pairs to maintain the correct brake balance. Important: FlIIlng a brake servo unit will not make faulty brakes reliable. Any fault In the vehicle braking system must be rectified. Therefore before fitting the new servo unit, ensure that the braking system is in good working order.
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Note: A. B. When changing brake parts the need for absolute cleanliness Is essentiaL Therefore ensure lhal hands are free of grease and dirt. Always use fluff-free cloth or paper towelling for cleaning purposes. Ensure a sufficient quantity of AP Lockheed DOT 4 brake & clutch fluid is available for bleeding tile braking system and topping up the reservoir. Where possible brake fluid should always be stored and dispensed from the original tin or bottie. Care must be taken to prevent both dirt entry and contamination especially in the mouth area of the master cylinder reservoir during this operation. N.B. AP Lockheed do not recommend the use of silicone fluid In any AP Lockheed products.

Prior to fltrnant of the brake servo unit or removal of an existing servo installation, thoroughly clean the outer surfaces of the unit (where applicable) and around all relevant hydraulic pipe connections using methylated spirit as a solvent. Do not use petroleum based products for cleaning braking system components, Le. petrot or paraffin. On the majority 01 vehicles a 3-way adaptor Is used into which are coupled Ihe supply pipe from the masler cylinder outlet port and the pipes feeding both Iront and rear brake assemblies.

Removing existing installation 1.

2. 3. 4. Disconnect Ihe battery. Disconnect and remove the vacuum hose pipe that connects Ihe servo unit 10 Ihe vacuum pump I manifold. Disconnect, remove and discard the hydraulic feed pipe from the master cylinder outlet port to the 3-way adaptor. Seal off the hydraulic connection points to prevent loss of brake fluid and ingress of foreign matter. Unbolt the existing servo unit together with any mounting brackets, where applicable, and remove from the vehicle.

Note: Brake fiuid is injurious to paintwork, therefore when removing the servo unit from the vehicle care should be taken to ensure that no fluid is spill onto the painted surface of the bodywork. Should fiuid spillage occur, wash off immediately with copious amounts of cold water. The following general instructions for AP Lockheed remote servo installation kits are supplemented by recommendations on servo applications for popular vehicles. Obviously all vehicte types cannot be quoted. bul by observing these instructions the installation kit can be used for the majority of vehicles with single line braking systems. Where the hydraulic piping, supplied in Ihe fitting kit, needs to be shortened Bundy flaring tool to reform the pipe end. it will be necessary to use a

Alternative Iliter cap

Retaining
cap Air control valve assembly

Rubber
seal

CompreSSion spring

Fig.'

Fitment of air control valve extension hose

-2 -

Location of new servo unit and brackets

" II is essential that the servo unit is fitted to the integral body or chassis (Le. not to the engine) preventing the brake pipes being subjected to vibration or flexing. unit and to keep the hydraulic pipe runs to a minimum length. thus

2a. It is an advantage to locate the servo within the engine compartment whenever possible to safeguard the
2b. Should it become necessary to fit the servo unit in an area on the vehicle prone to dirt, grit or water ingress e.g. under body wings, It is recommended that an extension hose be fitted to the air control valve inlet by carrying out the following modification, prior to installation. Method: Carefully prise off the plastic air fitter cap. Note components retained by the cap, which is a snap fit, may become dislodged during removal. Therefore care must be laken to prevent parts becoming lost or damaged. Extract the foam washer from within the exlstin~ air filter cap and replace inside the alternative cap, part no. 3887-266 supplied separately. Fit the new air flfter cap to the air control valve ensuring that the rubber seal, seal retaining cap, compression spring and filter element are all correctly located. (See Flg.1 for details). Connect one of the vacuum hoses from the kit to the inlet pipe on the filter cap, secure with cnp provided. On installation, locate the other end of the vacuum hose in a suitable position away from dirt or grit. 3. 4. 5. Ensure the hydraulic slave cylinder is at least six inches away from any part of the vehicle exhaust system, otherwise fluid vaporisation from local heat could occur. The servo unit need not be mounted below the level of the brake fluid reservoir, but keep the difference in height to a minimum. With the aid of the mounting brackets and fixings provided in the kit install the servo unit with the hydraulic slave cylinder outiet port inclined upwards between 25" and 45' from the horizontal plane. (See Flg ... 2). The air control valve should be situated at least 30' belOW the centre line to assist when bleeding the hydraulic system. (See Fig.3).

Can be either two stud

Air control
valve

or three stud ""'ng, d"pendlng upon the servo unit beIng litted

'P' shaped steady bracket

Servo unit

non-return
valve

Pos"ion of 'I.: shaped mounting bracl<et may need to be modlned to

suit Installation

Feed pipe trom single line brake master cylinder fanned to suit Installallon

(where fitted) and

petrol 'U' lrap

nen-retarn

valve

Fig.2
·3·

Fig.3 Fitting hydraulic piping

With all relevant connection points clean and free from ingress of foreign matter, using the new Bundy piping supplied in the kit a. b. Connect up the feed pipe from the brake master cylinder to the servo slave cylinder inlet port. Connect up the supply pipe from the servo slave cylinder cutlet port to the 3-way adaptor.

When bending brake pipes to shape, great care must be taken to avoid k.inklng. The best way to obtain a good curve is to bend the pipes smoothly round a mandrel of suitable diameter. Using existing clips on the vehicle, ensure pipes are properly secured and cannot chafe or foul other components. Where a long length of piping is fitted e.g. from one side of the vehicle to the other via the bulkhead, secure the pipe to the bulkhead 10 avoid vibration. Additional pipe clips are avaflable for use where necessary: On some vehicles where space is limited, it will be helpful to use banjo and bolt filUngs in the tappings of the servo slave cylinder to avoid a severe bend in the brake pipe. (See Fig.4). Nole: No attempt should be made to cut and reflare existing brak.e pipes in situ, as problems contamination through ingress of foreign matter, I.e. swart. could arise with

Vacuum hose, In line non-return vaJve (where fitted), and fittings

The servo unit must be connected via a vacuum hose, running from the plastic non-return valve located in the servo shell to a suitable vacuum source e.g. the engine induction manifold or vacuum pump. On some vehicles the manifold is already tapped and fitted with a removable plug, otherwise it will be necessary to drill and tap the manifold. Three manifold adaptors are available, each with a different thread size to suit various applications. These thread sizes are:-

1.

1/8" B.S.P. taper. This is self-sealing and should be used when the manifold is not already tapped. Drill the lap wall of the manifold 5116" and tap with a 1/8" B.S.P. taper tap. The manifold should be removed from the engine for this operation.
518"11:16 Whitworth thread. (Usa with a capper gasket).

2.

3.

518" x 18 U.N.F. thread.

(Use with a copper gasket).

Fit the relevant adaptor (and the copper gasket, if a 518" diameter adaptor is used), and attach the vacuum hose from the kit, securing with one of the hose clips provided,
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In a convenient position, preferably at the highest point in the vacuum hose run, an In line non-return valve is advisable on high performance vehicles. Cut the hose and connect up the two sections to the valve unit, secure with hose clips supplied. Ensure that when fitted the arrow on the non-return valve Is pointing towards the servo. (See Flg.4). Important: To protect the servo unit and non-return valve from fuel contamination, vehicle, a 'U' trap must be formed in the vacuum hose route. especiaUy on a petrol engined

lt Is essential the vacuum hose inclines downwards from the servo and that the 'U' trap is formed below the level of the servo and the In line non-return valve (where fitted), l.e. by looping it between the inlet manifold and non-return valve so that point 'X' is lower than points 'Y' and 'Z' as shown (see Rg.4). Where the vacuum hose traverses the engine secure in position with plastic ties. Secure hose connection at the servo with the remaining hose clip.

Bleeding and testing system 1. 2.

Reconnect the battery. using new AP Lockheed DOT 4 brake & clutch fluid or fiuid as recommended by the vehicle manufacturer (conforming to SAE J1703 specification) bleed the braking system In accordance with the appropriate vehicle manufacturer's workshop manual. With the system properly bled, firm resistance should be telt at the brake pedal. ifdifflculty Is experienced in achieving a "good bleed", then the bleeding process will be assisted by "cracking open" the brake pipe tube nut at the servo outlet connection whilst depressing the brake pedal. Surround this connection with clean "fluff free" cloth to capture escaping brake fluid. When the pedal is fully depressed ret!ghten lube nut, repeat this process several times if necessary. When completed, ''top up" the flUid reservoir to the correct level. Start the engine and apply the brakes several limes. Whilst an assistanl depresses the brake pedal, re-check for fluid leaks partlcuiarly where new connections have been made. Road test the vehicle, anc finally check again for fluid leaks.

3.

IMPORTANT:
Position 01 In line non-retu rn val VB (II fitted)
AT IN LINE NON·RETURN VALVE TO HOSE WITH THE ARROW POINTING TOWARDS THE SERVO

Single line bra.ke masler cylinder

~
To front brakes Removeexisti n9 brake pipe

't

manifold

supply pipe

New

j
To rear brakes Allernative hydraulic fittings

Fig.4

Schematic layout of brake servo unit and relative components

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General application guide for remote servo assemblies

Vehicle application ALFA ROMEO
1750 Berllna G1.. Saloon, Spider Veloce 80 } Coupe GT Velooe Al~ 80F\2 Commercial lEl0117

Installation kit {servo JENSEN

VehIcle application

Installation kit I servo

541 S Saloon lrom en""si. C·VB Mks.I.11 80111

10011001

LR17551 LR17551

ALVlS
3-litre 10rum brakes only) LE10117

MG
MGA (All models) 1.1GB 8. MGB-GT or lFl17814 MO Magnolia Mks. III & IV MG 1100 M.G Mldgel Mks. I, II 8. III LE72696 LA17S12 LA17914 LE72600 L.E72Sge or LA17814

ASTON MARTIN
3. Nit", 054 Saloon 80Vanlage. OT Sports Coup~ c-fitra OB6 Spt$. Saloon /l. Volanle Iwllh twin servos fille") FJD<11 Rear osse, OBS V-8 & V-8 Spons Saloon GT up to 1973 V-8 lrom 1973 !.agonda V-8 O.H. C. !.agonda 2. 112-llI(8 M... I & II and 3 I~ro (E_pl where servo Is already litled) LA17551 LR1S230 LR17818 LA1B504 LA18503 LR1B503 LE10117

ROVER
2000 PS from chassis Suffix C 2200 LR19230 lR16230

A.T.S.

aso

TALBOT (Hillman, Singer, Sunbeam)

G1.. LR17551 H,llman Imp Mk:s I & II, Caillornian fiJlIman Min. (Ali mod.ls) Hinman Husky (All mo"els) Hillman Super M,nx Mks.l. II. III. IV (All modals) Hillman Hunler Mks. I & II Hillman Avenger Saloon Ol. Super, GL 4 cyl Singer Chamois Mk s. I & II. Coupe SI ng. r Gazene (All models) Sinil:r Vogue M.s. I - IV up 10 Sept '68 Scm earn Alpine F H. Caur><! Sunbea.m Alpino sertss II Sports Tourer Sunbeam Rapier (All mcdets! lE72696 lE72696 LR17792 LRl7792 LAl7792 LAI7792 LE72696 LE15141 LE15741 lEl6741 LE15741 LE15741

AUSTIN I MORRIS
Austin Hoaley 100--Si. Au5lJn Healey Spo'" M"'_I. II. III & IV LR17551 LE72696 LR17B14 LE10,17 LE12896 LE72596 Lfl17814 LE72696 lE72696 LR17813 lcFl17813 or lE72696 LE72600 LE72Gge

or

Auslln I Morris 11 00. , :>00. 11r>eludlngall va rlan ts) Austin I Morris 1300 Or. Mini 8W & 1000. Countryman. Clubman Ilociuding all vananls) MIni-Cooper Mks. I /l. II Mini 127SGT Mini-Cooper'S' Morris Minor (All modals) Morris O~lord 'Farl",,' senes V & v11A11models)

~:::~~~~eU,-\~ciY:'IF TYpe 803000

TflIUMPH
Triumph Herald (All models) Trrumph 1300 Saloon Triumph Toledo Saloon TriumphTA3 Trlumpn 1.R4 & TR4A Roadster & Cour><! Triumph Spllflre Mt<s_II. III /j, IV Triumph GT6. Mks.l. II & III Triumph V.I"sse 6, 2-lItre Saloon & Corwernbte MI<s.I&1I LE726ge LE72696 LE72600 LE72Sge LE72600 LE15741 LE72696 LE72696 LE15741

or

BEDFORD
CA HC, JC .. PC Vans lE72696

BRISTOL
~OO,401,402, 40380 405 (Drurn brakes only) 4i.19,4)0 .• " & .12 LE10117 LR 18503

VANDEN PLAS
Princess 4·111",R LAl8503

CARBOOIES
FX4

T!I.,

LE15370

DAIMLER
Ma estle Maior DQ 450/1 up 10 cnassis 136572 tmm chas.is 136573 SP25D V-8 & 2.1/2-lIl1e V8-250 (Jaguar Body)

GtRLlNG (Interohangeabillty)
Lfl17551 LA17551 LR18503 LR17552 Appllcallon Allsil n & Moms 1BOO Au-sUn Healey 3000 Aston Marti n Commer 'Walk Ttmr Corlino lotus 125E Ford Corsair 120E GiMing Power Step Kits Land Rover LW B. LaJid Rover S .w.B. Leyland EA. Van t.otus Elan F.H. Coupe +2 Lotus Elan + Sprint MGC Mmgan Plus Eight Sperm 2-slr Morrls-Commel'Clais Aetianl Sclm.l111 F.H. Coupe GT Aover 95, 100 (P4) Vauxhall Vtva HB Vol"" P1BOO Girllng part no, 64049354 64049126 AP lDckheed part no. LEl0117 LE10117 LE10117 lE10l18 LE15741 LE10117 LE72696 LE72696 LEl0118 LE72696 LE10118 LE10117 LE72696 LE10117 LE72696 LE72696 LEl0118 lE15741 LEl0l11 LEI5741 LE15741

Mal'Mlle Malor 4.5-lilre OA4SO

DENNIS
ED.4 Ambul""",, LElOl17

64049460
64049183

FORO
Angll" I OSE, Super 123E Capri 1300 & 1600 up te Sepl70

64049127
64049408 6494OO~ 64940077

1~£ Mks. I & II Cortina 1600E, Gr. Corsair 120E. G T. V4 ESCQrt 1100 8. 1:>00 MI<. I Zephyr. Zodiac. Consul Mk. II (Drum brakes only)

co~:e\~~~~ r;oo""~~~o

LE72696 lE72696 LE72696 LE15741 lEl5741 lE72696 lR17814

6~04g354
64049179 640493:;4 64049330 64940000 64049326 64049127 64049126 134049314 640491~2

74849!J26

JAGUAR
2.4, 3.4 and 3.8-lIlre 240 and 340 series LA17552 LR17552 } Single syslems only lE10117

XK 12 Mk s, I & II
XK.I20e '>;K.140 XK.1S0

sa.

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Tachbrook Road, Leamington SP~Oducts UK Automotive ON AUTOMOTI.E .AOD~C;SwarkS, England, CV31 3E

GflClUP COMPANY