2nd Gen Non-Engine/Transmission Need Help: Hydraulic brake booster leaking PS fluid

[JGK]

The hydraulic brake booster on my '98 12-valve started dumping power steering fluid out of a small, approx. 1/8" hole on the bottom of the booster housing yesterday just as I pulled into the driveway. It's definitely PS fluid because it drained the pump! This morning, with the engine cold and after adding more fluid to the PS pump, it would only spew fluid when the brakes were applied.



Can anyone tell me what this small hole is for and why it's suddenly dumping PS fluid? What's the fix? My Dodge service manual does not mention it. It is obviously there on purpose - it is too round and perfect to be a housing failure.



Thanks in advance,

-Jay

 

[GAmes]

Jay, I'm on the road so don't have a mirror to look at mine but the only fixes I can think of require removal. If there is enough metal maybe you can tap some threads in the hole and insert a plug. Otherwise it is replacement time. IIRC the cost wasn't too bad when I had to get a new one.



Gary

 

[DEdwards]

It's a weep hole, kind of like on a water pump. The booster is shot, time for a new one. As far as I can tell, they are not rebuildable

 

[JGK]

Well, I did searches on this site, Competition Diesel, NorthWest Bombers, and Cummins Forum sites and no one mentioned this hole. A weep hole or an access hole for a punch to pop a retaining ring out when rebuilding the thing seems to be the only explanation. In any case, I think the diagnosis that a seal is gone and it needs replacing is the correct conclusion.



Gary, I think plugging the hole is probably only addressing the symptom, not the problem. A plug of JB Weld sounds like a quick, on-the-road fix to get to a shop (sounds like something you could relate to? )



In the searches the only thing that was said was warnings against A1 Cardone rebuilds, but, unfortunately, that's the only one available from all the parts stores around here. So it's that or buy a new one from the dealer or try to find one in a wrecking yard.



I found a rebuild from Schucks/O'Rielly locally (Cardone, of course) and put it in last night. So far so good. Fingers are crossed.



-Jay

 

[GAmes]

Gary, I think plugging the hole is probably only addressing the symptom, not the problem. A plug of JB Weld sounds like a quick, on-the-road fix to get to a shop (sounds like something you could relate to? )

I was thinking that possibly there was some type of plug pressed into the hole that had popped out. If it is a weep hole then obviously replacement is the only answer. Talking about on the road fixes, I stopped for fuel and couldn't restart the engine. I popped the hood to see if the fuel solenoid plunger was up and found the rod dangling from the fuel shutoff lever, it had popped out of the bottom of the plunger I carry a roll of . 032 stainless safety wire and using the skills learned as a helicopter mechanic I wired the rod to the plunger spring. That was a week ago. I'll be home tomorrow, so it has to work for a few more startups. I'm hoping I can find someone who had a solenoid failure but kept the plunger/rod assy.

 

[JGK]

Necessity breeds ingenuity. It's amazing what one can come up with as a temporary fix with a few simple tools and supplies and a some mechanical know-how.



-J.