HYDRO-BOOST BRAKE BOOSTER Installation Guide

930394-52 Rev. 12/22/05 4:21 PM Page 1

HYDRO-BOOST BRAKE BOOSTER BLEEDING THE HYDRO-BOOST (continued) Installation Guide 4. Enable ignition system and start the 7. Check fluid level and add fluid if engine. needed. 5. Turn the steering wheel from stop to 8. Again start engine and turn steering stop several times. Do not hold it wheel from stop to stop several times against the stop. (avoid turning fully against stops as 6. Stop the engine and then discharge much as possible). Recheck fluid level REMOVING THE ORIGINAL POWER BOOSTER pressurized fluid from the accumulator and fill as required. If there is evidence NOTE: Before beginning work, be sure by pushing on the brake pedal 4 or 5 of fluid foaming, turn off engine and 5. Disconnect the Hydro-Boost pushrod vehicle is parked in a level area and that times. wait an hour for foam to clear. linkage from the brake pedal. wheels are chocked to prevent unintentional NOTE: It may be necessary to remove the movement. Read all of these instructions stoplight switch from the brake pedal. If before attempting to install the Hydro- so, unplug the stoplight switch wires, Boost unit. remove the hairpin retainer, slide the switch 1. Disconnect the ground cable from the off the pedal pin just far enough to permit TROUBLESHOOTING battery. Get rid of any fluid stored removing the switch from the pin. Do not THE SYSTEM under pressure in the Hydro-Boost damage the switch. unit by applying the brakes several times. STOP-LIGHT SWITCH You will notice a change to a hard pedal when all pressure has been HAIRPIN CLIP relieved.

2. Remove the nuts attaching the master BRAKE PEDAL cylinder to the Hydro-Boost unit. PUSHROD 3. Separate the master cylinder from the PUSHROD SPACER mounting studs. NOTE: DO NOT disconnect the brake

AND POSSIBLE SOLUTION PUSHROD BUSHING lines from the master cylinder unless necessary to avoid bending or damaging those 6. Loosen the locknuts holding the Hydro- USE lines. Boost unit to the firewall and then PROBLEM

CA slide the linkage, nylon washers and Loose or broken power steering pump drive belt Low fluid level in reservoir Fluid return line restricted Dirt/Debris in Hydro-Boost 4. Disconnect all hydraulic lines from the brushing off the pedal pin. Lacks Power Assist X X Hydro-Boost unit (pressure, steering gear X and return lines). Booster or Pedal Chatters XX PRESSURE LINE SPACER Brakes Grab MASTER CYLINDER HYDRO-BOOST X Pedal Returns Slowly X Looses Reserve Pressure XX

MOUNTING RETURN LINE NUTS BRAKE LINES DO NOT DISCONNECT PRESSURE LINE JDA356 930394-52 1 930394-52 Rev. 12/22/05 4:21 PM Page 2

4. Install the stop light switch and it’s REMOVAL (continued) REPLACE BAD HOSES ALWAYS FLUSH SYSTEM retaining hairpin clip. Connect the 7. Remove the locknuts retaining the Inspect ALL power steering hoses. If a stoplight switch wires. When any part of the power steering Hydro-Boost unit and remove the unit leaking or soft, spongy hose is found, system is replaced the system should 5. Securely tighten the lock nuts holding from the firewall while sliding the replace all hoses. If any one hose is bad be flushed as follows: the Hydro-Boost unit to the firewall. pushrod out of the engine side of the the others are likely to also be ready to 1. Disconnect return hose from power firewall. fail. 6. Install the master cylinder onto its steering pump and place end of IMPORTANT: Be sure to save any nuts, Not all hose defects can be detected mounting studs on the Hydro-Boost. hose in waste oil container. bolts, spacers or non-riveted mounting from outward inspection since they Tighten securely. 2. Using fluid specified for vehicle, fill brackets since they must be reused when usually fail from the inside out. Deteriorated 7. Connect all power steering hydraulic pump reservoir. Start engine and installing the replacement unit. These parts hoses produce debris which will lines (fluid pressure, steering gear and keeping reservoir filled, run engine are critical to the operation of the replacement damage all parts of the system, including return) to the Hydro-Boost. until fluid flowing from return hose the Hydro-Boost unit. If a unit is Hydro-Boost. NOTE: Whenever the Hydro-Boost is removed runs clear. A second person should damaged by such debris the warranty is turn steering from stop to stop 8. Put the old Hydro-Boost into carton void. the power steering system must be bled. to assure proper core credit upon return. during this process. Ne ver let pump Use only the Power Steering Fluid specified run without fluid. by the vehicle manufacturer in the power INSTALLING THE HYDRO-BOOST UNIT steering reservoir. 3. Reconnect return hose and fill reservoir to proper level. 1. Install spacers, gaskets and/or mounting brackets from the old unit onto the STOP-LIGHT SWITCH replacement unit. BLEEDING THE HYDRO-BOOST 2. Mount the replacement Hydro-Boost HAIRPIN When any part of the Hydro-Boost system Use only DOT-3 or better Brake Fluid in to the firewall but do not tighten the CLIP is replaced the power steering system must the brake master cylinder reservoir. mounting nuts at this time. Be sure to be bled to eliminate trapped air. guide the pushrod into place without 1. Fill power steering reservoir to the applying any damaging force to it. Do BRAKE PEDAL CAUTION: Be very careful to avoid bottom of the filler neck with specified not force the rod in any direction as getting even a single drop of fluid into a fluid. PUSHROD part of the system where it does not belong. this will damage the unit an void the 2. Disable ignition system to keep the PUSHROD SPACER Power steering fluid and brake fluid must warranty. engine from starting and then crank not be mixed. Power steering fluid will the engine for several seconds. 3. Connect the Hydro-Boost pushrod to damage brake system seals on contact. If the brake pedal. Make sure the nylon brake fluid contacts power steering seals 3. Check fluid level and add fluid if PUSHROD BUSHING washers and brushing are installed in they will immediately be damaged. needed. their original positions.

PRESSURE LINE MASTER CYLINDER SPACER HYDRO-BOOST HYDRO-BOOST RETURN LINE MASTER CYLINDER COOLER RESERVOIR PUMP & RESERVOIR

MOUNTING NUTS PRESSURE LINES BRAKE LINES RETURN LINE DO NOT DISCONNECT PRESSURE LINE

2 3 930394-52 Rev. 12/22/05 4:21 PM Page 2

PRESSURE LINE MASTER CYLINDER SPACER HYDRO-BOOST HYDRO-BOOST RETURN LINE MASTER CYLINDER COOLER RESERVOIR PUMP & RESERVOIR

MOUNTING NUTS PRESSURE LINES BRAKE LINES RETURN LINE DO NOT DISCONNECT PRESSURE LINE

2 3

930394-52 Rev. 12/22/05 4:21 PM Page 1

2. Remove the nuts attaching the master BRAKE PEDAL cylinder to the Hydro-Boost unit. PUSHROD 3. Separate the master cylinder from the PUSHROD SPACER mounting studs. NOTE: DO NOT disconnect the brake

MOUNTING RETURN LINE NUTS BRAKE LINES DO NOT DISCONNECT PRESSURE LINE JDA356 930394-52 1