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Hydroboost making me pissy

pseudomike

1/2 ton status
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May 11, 2007
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Ok guys a little long but if you got a minute could use some help.

Trying to help a good friend out and I think we have some sort of hydroboost problem. He has a truck that has sat for 4-5yrs that he is trying to get up and running. So I have been giving him a hand here and there changing the transmission and so on. Early on we noticed the PS gear box was leaking so we purchased a napa replacement for the old girl. Everything was ok for the first few weeks and then the PS pump belt started squeaking like mad. He went down, bought a new belt and installed it. The pump was still squeaking so I told him I'd come take a look. After messing around with it for a while I noticed that the PS pump had a ton of play in it so I told him to got NAPA and pick up another pump as it must be toast from sitting. Couple weeks later we got around to installing the new pump (pump complete w/resevoir). I brought over a pulley that would fit all sandblasted in hopes that may help. Fired the truck up, no more squeak but now the pump is whining like it's low on fluid. I figured we rushed something, cracked a hose, didn't bleed it enough or something and it was getting air. So I let the truck sit overnight, went back the next day, replaced all the return hoses, re-bled the system, and fired it up. No whining. Take the truck for a test drive, brakes are good, steering good, but about 10 minutes in the pump starts whining again like it's out of fluid. So we pulled over, checked the fluid and it was all set but looked like it was foaming w/air. At that point I told him to bring that pump back to NAPA and pick get a full set of hoses because it must be leaking air somewhere. So another few days passes, we get the hoses on, get the new pump on, get the system flushed and bled with synthetic oil, and off we go again....ten minutes down the road whining like a Ford. So we drove the truck home, same deal, foamy fluid (air bubbles). I also noticed that the pump sounded like it was straining so I started poking around. Ouch!!! the pressure hose to the hydroboost was like a bazillion degrees. Now this has got me thinking that the problem may well be something with that hydroboost unit. I've never really tinkered with these too much but I assume it is possible that it is sticky, or has some seals leaking air? The brakes feel fine though, and the truck is steering ok and aside from the really loud whine and foamed up fluid it drives fine.

Is it possible that the booster could cause this problem? There is no visible leakage around it or anything of that nature. I'd hate to have this guy go pick a booster up for a $150 if he doesn't need one because he doesn't have that type of change to spare. I'm tempted to return another pump to NAPA first but I think they would get fairly pissy if we pick up too many more. I really don't know. Anyone seen this type of behavior before?
 
How did you bleed the system? The hydro-boost takes longer to bleed and you have to take into account the brake booster (forget the exact order, but during bleeding at certain points you have the pump the brake pedal).
 
I had the same deal on my 6.2 k5 years ago.

The solution was to constantly pump the brakes as you steer side to side and it took a long time. IIRC it took several tries to get it all bled out. Once the fluid got foamy I would let it sit for a while with the cap off the res. Once all the bubbles had gone I would pump the brakes and steer side to side again. I was afraid of overheating the fluid, hence the reason for letting it sit once it got foamy.
 
I too noticed the hydroboost setups take more bleeding time. I agree with the bleeding procedures above. Work the system for a little bit, then let it set to settle back down. I remember thinking it was never going get better, but it ultimately did.
 
Ok, well we got another pump on order. After checking all hoses again, replacing the booster, and replacing the fluid we tried bleeding it again. This time with the engine off we turned the front wheels back and forth about 250 time (no joke). Absolutely no air in the reservoir whatsoever after performing this. Start the truck and within say 5 seconds instantly foamed up. Also noticed that the return line is flowing so much volume that it causes so much turbulence that even at idle it will literally blow fluid right out of the reservoir when the cap is not on. I checked all of my trucks and I can barely see the fluid moving so I am assuming there is some sort of drastic issue with the pump. I will post back when we get the new pump to see if it fixes it.
 
What about the air that is, was, could be, in the brake booster

Isn't the res a remote one ? should it be ? not enought fluid your problem ?
 
Yeah, we though about that. We did pump the brakes when turning the wheel with the engine off. We even tried clamping the return on the booster off to see what happened. No fluid comes out of the booster return until you step on the brakes, it seems that it all goes through the gear box return hose. I have a hydro booster on my 1 ton. I had no-where near this much trouble when I overhauled the entire system. I didn't even bleed that system, added fluid, started it up, idled about 5 min and drove away. Not a problem since? I pulled the cap off the pump on that truck when it was idling and I could barely see the fluid moving. The truck with the issues looks like old faithful...never seen anything like it.

If another pump doesn't cure it I guess it's time to goto the dealer and let them figure it out.
 
yeh the booster doesnt get 'flow' unless you are on the brakes, then when you step on them you get fluid flow through them. I had the front of mine jacked up, cycled the wheel with the engine off and got some air out, pumped the brakes a couple times got a little more out, then I started it and held the brakes down and cycled the wheel back and forth. Got like 90% out, then the rest bled out driving it around the neighborhood.
 
Well, replaced the pump again....had to cut the pulley off with a torch because the pulling flanged cracked...thankfully I had a spare. Buttoned it back up, added fluid, fired it up, and off we went. No whining, natta, didn't even have to bleed it. I guess we had a few Monday morning pumps in there or something? No clue but it's working now.
 

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