2nd Gen Non-Engine/Transmission vacuum to hydroboost conversion?

[SRath]

Has anyone converted their early 2nd gen from vacuum brakes to hydroboost from a later model? Is it straightforward bolt-in swap or are there any complications? Mine is a '96 and I'm looking at buying parts from a '98.

 

[Gene Heck]

It is pretty straight forward.



I did the same to my 96 that your thinking about doing. I used a 98 as the donor. Make sure that you get all the hoses and metal lines from the donor especially the metal lines that connect the hoses to the hydroboost. Your 96 power steering pump only has 1 return fitting so you have to tee the return from the power steering box and the return from the hydroboost together or change to the 97 or later PS pump which has 2 returns already on it. I teed mine and it works okay.

The other thing is the 96 master cylinder mounting holes are a little closer together than later models so you either have to elongate the 96 master cylinder holes a little and you have to shorten the pushrod a little between the hydroboost and mastercylinder. If you choose to use the later style master cylinder the brake line fittings are different on the master cylinder and will have to be changed or adapted. Other than these items it is a straight forward changeover. I chose to keep my original master cylinder. The push rod is easy to cut and file or grind a new round end on it.



It works good. I'm glad I did it and wouldn't go back.



You still won't have the stopping power of a later model truck but it will be much better than what you have now. A key to the older rear drum brake trucks is to make sure that you keep the rear brakes adjusted up which ever type of boost you have.

 

[SMorneau]

I did the conversion a few months ago and I am very pleased. I bought a hydroboost unit from a wrecked 01 and got new hoses from rockauto, T-ed in the return line and added an extruded aluminum cooler to the from cross member.



If you have a donor and a few bucks for new parts like a new MC and some new hoses it's pretty simple. I used my existing PS pump and it is working just fine. If yours it weak it may not. Oreilly had a good selection of brake fitting adaptors to make it all work.



I had some issues getting the system bled but with some patience we got it bled. There are some good posts and links on this site about the conversion. It's also easier to get to the fuel filter now.



Scott

 

[SRath]

I got all the lines, but got outbid on the hydroboost. Shoulda bid more, but the front suspension is decimating my life savings at the moment. Maybe next time. I'll get one eventually. I appreciate all the good info guys!

 

[Gene Heck]

Just make sure that you get the hard metal lines that go onto the hydroboost. They are prebent and I don't think they come with the hoses when you buy replacement hoses. They are between 6" to 1' long with several bends made into them. Just make sure that when you buy a hydroboost that the seller includes these. With the hoses that you just acquired go look at a a 97 or newer truck to see what I mean if your not familiar with the setup. It's not hard but one missing piece like those metal tubes will screw you up for a while until you get them.



Gene

 

[SRath]

This is what I got Gene. Does it look complete? :

02 Dodge Cummins Turbo Diesel POWER STEERING LINES hose:eBay Motors (item 360192569600 end time Sep-29-09 18:59:43 PDT)

(note: the photo turned out real small. This link takes you to the auction photo which is larger. )

 

[Gene Heck]

Yes, the two metal lines near the bottom of your picture with all the bends in them was what I was referring to. Your on your way. I have bought stuff off of REDLINEAR a few times now (probably about 10) and his shipping is a little pricey sometimes but the quality of his stuff is good. Save him as a favorite vendor. He takes quite a few trucks apart plus he breaks them down to the nuts and bolt level in case you need an odd assortment of "stuff".



Gene

 

[SRath]

Yeah, I have bought a lot of parts from him, too. The shipping for a single item can be high, but he does combine shipping on multiple items. I bought some used intercooler boots (my passenger side one looks to be sliced halfway through by the sharp lower edge of my inner fender) and an NV5600 mount plate along with the lines this time and he only charged shipping for one item.



I bought my door panels, wiring harnesses, switches, motors, lock actuators, etc, from him when I converted to power windows and locks. Also a NV5600 crossmember and other parts. Sometimes I wish he wouldn't separate parts of a single system (this hydroboost and lines and master cylinder, for example) into separate auctions. It is tough to be high bidder on several auctions ending all at once. Then you run the risk of ending up with parts you can't use because you didn't get everything you need, like happened to me this time.