My hydro-boost is leaking on my 2002 Duramax. I checked with a local dealer and they wanted over $750+tax to replace. The part was almost $500!!! The dealer said they do not rebuild...they only replace. Warranty is out of the question as I turned 98K yesterday and don't have an extended warranty. My questions are...

- Is there a rebuild kit (gaskets) for the Hydro-boost?
- What is the part number?
- How difficult of a project is it to put on?

Any thoughts would be helpful.

Thanks,
Steve

1) No rebuild kit avail. from GM
2) Don't have the part #, but you may price one from Eric,Napa, Autozone, etc...
3) Pretty simple, no special tools needed.

Thanks Max.

Does anyone have a few more details on the install?

I have found the part number and the part on-line for 1/2 of what the dealer wants for it.

Hydraulic Brake Booster Replacement

Caution: Refer to Brake Fluid Irritant Caution in Cautions and Notices.

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Cautions and Notices.

Notice: Hydraulic brake systems use two distinct and incompatible fluids. Power steering fluid is used in the hydraulic brake booster system. Brake fluid is used in the master cylinder and brake pipes. Use extreme care when selecting brake system fluids, or seal damage can result. Refer to General Information to select the correct fluid.

Checking and Adding Fluid

For information on checking and adding fluid to the hydraulic booster system, refer to Checking and Adding Power Steering Fluid in Power Steering System.

Bleeding the Hydraulic Booster System

Refer to Bleeding the Power Steering System in Power Steering System.

Flushing the Hydraulic Booster System

Refer to Flushing the Power Steering System in Power Steering System.

Removal Procedure

<LI type=1>Apply the park brake and block the wheels. <LI type=1>Disconnect the inlet hose, the steering gear, and the return hoses from the booster assembly. <LI type=1>Remove the master cylinder. Refer to Master Cylinder Replacement . <LI type=1>Remove the stop lamp switch. Refer to Stop Lamp Switch Replacement .

<LI type=1>Remove the 4 booster to bulkhead nuts. <LI type=1>Remove the booster assembly.
Remove the gasket.
Installation Procedure


<LI type=1>Install the gasket. <LI type=1>Install the booster assembly. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

<LI type=1>Install the 4 booster to bulkhead nuts.
Tighten
Tighten the nuts to 36 N·m (26 lb ft).

<LI type=1>Install the stop lamp switch. Refer to Stop Lamp Switch Replacement . <LI type=1>Install the master cylinder. Refer to Master Cylinder Replacement . <LI type=1>Connect the return hose, the steering gear, and the inlet hoses. <LI type=1>Bleed the hydraulic booster system. Refer to Bleeding the Power Steering System in Power Steering System.
Release the park brake and unblock the wheels.

You do not need to disconnect the brake lines from the master cyl. You can move it far enough out of the way to get the booster out.

Thanks!

Max -

I decided to give it a go...I purchased the part in locally at a new dealership. I didn't get the part as cheap as I could have on-line, but they gave me a very good price and I didn't have to worry about it being knocked around during shipping.

I do have 2 more questions...

During the removal procedure step 2 it refers to "the steering gear"...what is the steering gear?

Is it recommended to replace the gasket mentioned in installation step 2?

Thanks,
Steve

Steering gear line is what they mean, there are 2 pressure and one return line to take loose at the hydroboost. The "gasket" is a reusable rubber gasket that fits between the hydroboost and firewall. It takes patience to remove the little black clip that holds the brake pedal rod/brake lamp switch. Save yourself the grief and get a new one, that way you can destroy the old one getting it off. Good luck.

Thanks again!

Replaced it today...it took a little over 2 hrs. I wasn't bad at all. The hardest part was getting the clip back in the brake petal!!!

Thanks.

Mine went out on my 1997, I got a hydrobooster and master cylinder from a junk for $100.00

I cannot beleive a seal kit is not available, come on what is it a couple of O-RINGS ??????

T:rolleyes: NY