Brake Booster Replacement Tips? '02 1500HD

I have an '02 Silverado 1500HD, 4WD Truck with 6.0L.

I need to replace the brake booster. I have a rebuilt ACDelco part on the way.

Can you please give me any tips or advice? Even step-by-step would be great.

I'm still learning to be my own mechanic :bigthumb:

find some you tube video on this .

make sure to old is exactly the same as new.

so why are you doing this replacement ? how did you come to this conclusion.

so why are you doing this replacement ? how did you come to this conclusion.
I have perused Youtube but some topics are covered better than others. Most of the videos cover the big round canister type boosters but my truck has the other kind. There is one video about this type of booster by EricTheCarGuy that is pretty good but he doesn't talk about any adjustments. Other sources seem to suggest that some booster types need installation adjustments.

I must admit I am relying on the diagnosis of a mechanic. We had him fix a power steering leak recently. It was good for a week, started leaking slowly, then quickly, and we took it back. He said the hoses he replaced were still solid but now I have a brake booster leak.

The brakes do seem a little weak although they work adequately.

explain weak brakes .

a high hard brake pedal can be the booster... or a vacuum leak at the booster. 1500 should use vacuum to create brake power.

2500 uses the power steering pump different system.

You likely have a HyrdoBoost system. The booster most frequently leaks from the cup seal for the piston and out the front of the unit. Leakage becomes apparent at the gap (drain) between the booster and rear of the maser cylinder. Repair is fairly easy, and replacement is just a little easier. Search for "hydroboost" and you'll likely get some hits.

The system will still require bleeding after the replacement.

So, I've got the unit replaced. It is a power steering pump system, probably because it is the heavy half (or HD).

I thought maybe I broke something because when I attached the brake master cylinder, it forced the plug out of the return line and shot fluid all over the place. Should this be expected if the plug is not first removed?

I'm really lucky the stuff wasn't blasted into my eyes. I'm amazed this is not a warning in the install instructions or on Youtube. Maybe I'll even put up a short vid about it.

Other than this snafu, everything went together fairly well. Could this have caused a problem?

The battery was too weak for me to bleed so I get a break for a few hours.

good you did fix it and no brake fluid in eyes...

responses to vehicle issue repairs do help many.

If the Hydro-Boost unit was pre-lubricated there is a chance that your installation forced the plunger back into the cavity (as it should) and the oil in the booster was forced out. This would be expected, but the normal procedure is to install the P/S pressure and return lines before mounting up the MC.

It is probably O.K. and you will find that out when the engine starts and build P/S system pressure. You'll likely have to top off the steering pump reservoir (power steering hydraulic oil ONLY, please!) and then bleed the brakes if you have removed the lines from the MC. It is possible to swap out the Hydro-Boost without disturbing the brake lines on the MC if there is sufficient surplus in the brake lines.

the normal procedure is to install the P/S pressure and return lines before mounting up the MC.


I was lucky this time. I will try to think more about proper order of operations more in the future!

I tried to bleed the power steering (twice) but no bubbles came up in my reservoir. Luckily I didn't have to remove any brake lines, etc, there is a lot of space around the master cylinder in this model.

Everything seems to be working great. I drove it to the coffee shop where I'm making this post. It steers without noise and stops just fine. I can't detect any leaks yet (which was the real problem I was trying to address) :iceslolan

Treat yourself to a coffee and stop worrying about it. Good repair.