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Discussion Starter #1
I replaced the hydroboost on my 96 6.5 and afterward the brakes are partially applied which progresses to fulling applying as they heat up. I have concluded the rod in the hydroboost must be slightly longer and when the master cylinder is bolted down it pushes in the piston. I have read online about a washer that can be missing that allows the rod to fall off center and not insert into the center of the master cylinder piston. It appears the washer is on the replacement booster and the rod is centered. I am going to also replace the master cylinder as well because it appears it was leaking slightly but I do not think that will cure this problem. Is there some sort of adjustment of the length of the rod I missed maybe from the pedal side? Otherwise what might I do to correct this? Can I insert a washer or 2 on the studs before mounting the master cylinder to shim it up? Or did I get a bad hydroboost?
 

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I have had a bad hydroboost out of the box. It failed in the opposite way. I had no hydroboost after install. I took it back and got another, replaced it, and it was working fine.
 

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Discussion Starter #3
The booster itself seems fine but appears the rod is just a little bit too long. If I loosen the master cylinder mounting bolts slightly it allows it to push back and release the pressure. I really do not want to have to pull the booster again.
 

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1995 Chevrolet Silverado Z71 6.5 TD
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I live in ca and I get mine rebuilt at a place in San Jose Ca> The cost is the same as a rebuilt ~$280.00 +tax. I physically took my HB down to them and watched their process they field strip boil out rinse and dry off parts.Then rebuild unit with all new parts greasing all points of contact and recharge the accumulator. Ive had mine now for almost a year with no issues. The nice part is that there's not wondering about fit. They are one on the largest power brake rebuilders in the US. They rebuild Hydroboost, Vacuum power brake units and Master cylinders. There might be one closer to where you live. pwrbrake.com
 
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