Next up: Hydroboost Brake Conversion
After hours (days?) of research I pulled the trigger on converting the truck to hydroboost.
Parts used:
Junkyard hydro boost unit and matching brake pedal. Off of a 93 6.5TD K2500 Suburban if i remember right.
All new PS and Hydroboost hoses and fuel line style hose clamps.
New PS pump (HB version w' 2nd return port), for a 3500 with a 5.7 TBI (so i can use the same assessory bracket). No fitment issues.
PS filter, inline, aluminium.
PS cooler (front/grill mount version).
New master cylinder for a 93 6.5TD K2500 Sub w' HB (matches junkyard HB unit)
Brass NPT plug to block intake vacuum port.
HB to firewall gasket.
There are already a good number of 'how-to's' on this so i didnt do a full write up/instructions but here are some thoughts/ideas to share on this swap. Feel free to comment or shoot me a PM if you have any questions.
1. Flush steering gearbox prior unhooking the old return line. I ran it into bucket, cranked engine over while dumping new PS fluid through PS pump. Pour FAST and DONT run engine as you will run the pump dry real quick. I disconnected the coil wire and cranked it in short stinits. Do it with the old pump still on preferably, i used the new pump as i wanted to flush the HB unit. FYI - I did it before installing the new PS cooler and filter to minimize old fluid contaminating new parts.
2. Source a matching HB Unit, pedal and master cylinder if possible. I did this for compatibility and peace of mind.
3. New hoses and GOOD new clamps. Just do it, you won't regret it.
4. Rebuild HB unit before installing when its out of the vehicle. I didn't bc the junker looked in good condition, no leaks and less than 200,000kms on it (thanks 6.5TD). I did clean and paint the outside.
5. Its a good time to upgrade your PS cooling system if you dont have one. Your now doing double duty with your PS fluid, steering AND brake booster. I went with the bigger cooler as Im hauling the camper full time. My factory, small tube style cooler in the frame rail was rust out so into the scrap pile it went.
6. I ran a new pump for the 2nd return port convenience as i didnt want to dick with Tee connections etc. I had read that HB PS pumps put out a higher line pressure, therefore more brake boosting ability. Can anyone confirm this? Im curious to know.
HB Pedal
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Shows HB mounting bolts and push rod installed
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Engine bay shots
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Ill grab some shots of the new PS setup next time I'm out at the truck