Archived Power Booster Leak

[OakViewJeff]

While traveling in New Mexico, I noticed a fluid drip under the driver side of my '99 2500 truck. Further inspection under the truck revealed the leak was coming from the 5 bolt flange between the steering power booster and the firewall support for the entire steering booster and master brake cylinder assembly. I checked all of the bolts and they are tight. I do not have my shop manual with me to understand what parts are inside that could have failed.

Is there an o-ring seal around the brake piston linkage that passes through the steering booster?

Anyone out there familiar with this problem?

Thanks
Jeff Hall
TDR Subscriber since 2000

 

[OakViewJeff]

I found the leak coming from the weep hole on the bottom of the hydro booster. I purchased a reman from Napa and will be installing it today. I found a great procedure in the 2nd Gen Engine and Transmission forum for removing and replacing the booster.
Jeff

 

[DavidC]

Glad you have a fix figured out and the replacement was already documented.

Dave

 

[OakViewJeff]

Dave,
Well, I'm still stuck in Socorro, NM! The reman hydro booster (HB) from Napa (A1 Cardone) was installed per procedures, but failed the diagnostic testing. The brake pedal is 1-1/4 lower than the clutch and the brake lights are always on.
1. Booster function test-Depress pedal with engine off, started engine and the pedal did not fall then push back like normal.
2. Bleed test- Removed the return line from the HB, plugged line and installed temp drain line. Cranked engine with fuel disabled, pressed the brakes 10 times, very little fluid coming out the return port.
3. Run engine fast idle, pull back on the brake pedal, then press down with 100 lbs force and pedal comes back to same postion, short by 1-1/4".

All dimensions check out, connecting rod to pedal, piston rod to MC, mounting bracket to firewall. Anyone else had this probelm with A1 Cardon reman HB?
Jeff

Called Napa and they said return it for another reman! Dealer wants $856 for a new one located in Denver!