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Illustrated Hydroboost swap

Excellent information! I do have questions tho...

Anybody here running hydroboost along with full hydraulic steering? Any pics of the setups? Did you have to port the hydroboost in order for the steering to receive enough pressure? How do you port the hydroboost?

Any info is greatly appreciated!
 
crawler78 said:
Excellent information! I do have questions tho...

Anybody here running hydroboost along with full hydraulic steering? Any pics of the setups? Did you have to port the hydroboost in order for the steering to receive enough pressure? How do you port the hydroboost?

Any info is greatly appreciated!
Click to expand...
I'm doing the conversion to hydro boost brakes now so I was looking at this during research. I didn't see many drawings or pictures for it, but I didn't look too hard. For full hydro steering, you port the steering box/gear to drive the steering ram. That's my understanding as I'm planning to add that some day. When I added cross over steering, I bought the pre-ported PSC steering gear so I have it ported already when I want it. Also, the PSC kit I was looking at includes a higher power pump and remote reservoir, so I figure that will increase power. There's also good articles in here on porting a steering box yourself. Sorry, I don't have those links saved or readily available. I hope this helps, while I don't have it hooked up now, I "over-thunk-it" a bunch... LOL!
 
I'm also doing this soon on my K5. Thinking of just ordering the cast iron master and booster from like an 84 K5 with diesel unless I should be doing a truck master for the D60/14 bolt. You can also get the updated plastic master but I'm worried about heat with my turbo headers running close and melting the plastic.
 
I have parts in storage. I got a great deal on a brand new hydroboost unit on ebay.....army surplus. Bought the disc/disc corvette master as well. My parts book shows that the brake pedal for my year (90) is the same no mater if its hydro boost and or vacuum brakes. The old problem is the 90 has abs so i have to hit a yard for lines to set it up as a 86 brake line wise.
 
what years and models had the hydro boost? do i need to change out my ps pump ?looking at adding it to my 84
 
73-87/91 All one tons and all diesels. The pump is different.
 
The kit i got was from ORD PSC SK320 and the #8 -#12 line upgrade
 
I'm trying to gather hydroboost info with the all the pictures, illustrations and written info. So much info on this and it can be overwhelming when trying to convert. It honestly needs to be a dedicated article which I may write up one.
 
Shawn said:
I'm trying to gather hydroboost info with the all the pictures, illustrations and written info. So much info on this and it can be overwhelming when trying to convert. It honestly needs to be a dedicated article which I may write up one.
Click to expand...

LOVE MY HYDROBOOST! I (unfortunately) had to use it 4 days after I installed on the crazy so cal freeways. I locked up all four for the first time in YEARS. saved my truck!

One of the single best articles:
http://forum.expeditionportal.com/threads/137837-GM-hydro-boost-brakes-for-newbies-like-me

Some additional links I stored
Hydroboost conversion links:

https://www.tonkinonlineparts.com/s...ake=1088&ukey_model=15787&ukey_category=22609

https://ck5.com/forums/threads/illustrated-hydroboost-swap.306221/

http://67-72chevytrucks.com/vboard/showthread.php?t=701079

http://forum.expeditionportal.com/threads/137837-GM-hydro-boost-brakes-for-newbies-like-me



Pump install/bleed instructions: http://www.rockauto.com/info/Atsco/220296 General PS Pump Installation Instructions.pdf

http://my.cardone.com/techdocs/PT 52-0001.pdf



Brake components (system)

https://www.tonkinonlineparts.com/s...ake=1088&ukey_model=15787&ukey_category=22609



Pushrod & spring

http://www.thehollisterroadcompany.com/hydroboost.html

2A9247EC-3246-9B42-B41B-F5575F46AA60.png


8AC40AB0-B48D-8644-879B-FD8CB978F099.png
 
PS: I have a complete spreadsheet with parts I used (w/ costs) for my 89 K5. You can PM me or email me (profile info) if you would like me to send the parts list.
 
cesandvik said:
LOVE MY HYDROBOOST! I (unfortunately) had to use it 4 days after I installed on the crazy so cal freeways. I locked up all four for the first time in YEARS. saved my truck!

One of the single best articles:
http://forum.expeditionportal.com/threads/137837-GM-hydro-boost-brakes-for-newbies-like-me

Some additional links I stored
Hydroboost conversion links:

https://www.tonkinonlineparts.com/s...ake=1088&ukey_model=15787&ukey_category=22609

https://ck5.com/forums/threads/illustrated-hydroboost-swap.306221/

http://67-72chevytrucks.com/vboard/showthread.php?t=701079

http://forum.expeditionportal.com/threads/137837-GM-hydro-boost-brakes-for-newbies-like-me



Pump install/bleed instructions: http://www.rockauto.com/info/Atsco/220296 General PS Pump Installation Instructions.pdf

http://my.cardone.com/techdocs/PT 52-0001.pdf



Brake components (system)

https://www.tonkinonlineparts.com/s...ake=1088&ukey_model=15787&ukey_category=22609



Pushrod & spring

http://www.thehollisterroadcompany.com/hydroboost.html

2A9247EC-3246-9B42-B41B-F5575F46AA60.png


8AC40AB0-B48D-8644-879B-FD8CB978F099.png
Click to expand...

Great info! Lots here, lots on other sites. Just takes awhile to absorb the right info and figure out a plan and where to find parts. The square body boosters are definitely getting harder to find but any GM booster works with the correct firewall plate. I asked Vanco if there is any difference on them and he said they were all the same (Astro, K30, etc). My local junkyard thought they had 3 of them but they were all vacuum boosters. That pushrod and spring link is gone. Someone was looking for that on another site. I'll contact you on your spreadsheet. Thanks!
 
I've been running hydroboost brakes along with full hydraulic steering on my off-road rig for almost a year now. No joke, the best brakes I have ever had! And hydro steer doesn't seem to be effected with stock hydroboost parts. I'm a crawlers tho, no high speed braking/cornering at same time. I did go with PSC pump on my 5.3 and have big PSC resevior with long tube cooler plumbed in. Dana 60s front and rear with jb6 calipers an all 4 corners stopping 42" tsls on H1 beadlocks no problem.
 
Doing some research for a future swap.
Does anyone know if there is any truth to the plunger, star retainer and spring being the same in the 80’s models brake booster all the way up to the late 90’s early 2000’s trucks.

From what I’m reading those three parts and the firewall mount bracket are all parts that do not come with a reman unit.
 
I was told you can those parts at http://precisionrebuilders.com. I thought the firewall bracket stays on since there is no way to get it off/on without special booster tools.

49845110_2297847553559425_1249786060947324928_o.jpg
 
Those look just like the parts I snagged today at the pull a part.

From a 98 model van with hydroboost
 
Can you verify the firewall plate if you get a reman? I just looked at mine at there is no way I can get that off without having this special tool. Its basically a square nut.

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s-l1600.jpg
 
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You do need the special tool. I ended up taking mine to a dealer and having them remove it for me.

Unfortunately, they didn't have the right tool either, so they used an air chisel. :angry1:

They did manage to get it off though. I made my own tool to put it back on, but it would never be strong enough to take one off that was really tight.
 
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