2004 GM LS 6.0 Hydroboost

[broncochevy]

Scored this today...This came out of an 04 GM LS 6.0 powered pickup. Is this any good. Read all kinds of stuff on Astro van hydros and found this first.
Got mc, booster, cooler, Saginaw dual return pump with pulley, and all lines (Except the one I noticed I left on accident). I actually got the serpentine bracket because I did not have a puller to remove the pulley, and they let me have it anyway.
So, is this setup any good? I know only what I have read here and got quoted 80 for Astro hydro booster with lines, and this was $95 with the pump, lines and booster with mc, and cooler. So I thought why not?
Teach me the way...

 

[toddz69]

Should work just fine.

Todd Z.

 

[broncochevy]

Todd, is there anything in the booster to rebuild/replace/reseal? Or is this something g that most just install without anything redo?

 

[toddz69]

There are some folks that rebuild/re-seal them. I haven't ever devoted the time to doing that - I've always just tried to use clean junkyard units for my installs.

Todd Z.

 

[broncochevy]

Thank you. I shall see what to do in the future. This one looks really clean, however, the rest of the system looked caked pretty bad. Seemed to be leaking from the steering box pretty bad.

 

[Tstinnett]

You may want to double check that master cylinder. 99-04 GM trucks were disc/disc and not disc/drum. After 05 many trucks went back to drums in the rear, but again there are a lot of variations.

I have seen quite a few of them in the yards on the XL, Denali and 2500 trucks. I’m curious if the bolt pattern on the mounting bracket is the same as the Astro? Astro donors are becoming more rare and I see many already pulled on my visits. How big a PITA was it to pull? I’ve got the Astro down to about 10 minutes in the yard.

I clean mine up, and run it straight from the yard. My first one developed a leak on the input shaft after about 6 months. I ordered a rebuild kit for 45$ then came across another good Astro donor I pulled, cleaned up, and installed and working perfect. Now I have a spare and a rebuild kit on the shelf. They’re under 30$ in my yards. I am also running 99 to mid 2004-5 GM HD 2500 dual return Saginaw pump on a Wild horses bracket with some minor massaging of the return ports to get them out of the inner fender.

 

[ChrisR]

You may want to double check that master cylinder. 99-04 GM trucks were disc/disc and not disc/drum. After 05 many trucks went back to drums in the rear, but again there are a lot of variations.

I have seen quite a few of them in the yards on the XL, Denali and 2500 trucks. I’m curious if the bolt pattern on the mounting bracket is the same as the Astro? Astro donors are becoming more rare and I see many already pulled on my visits. How big a PITA was it to pull? I’ve got the Astro down to about 10 minutes in the yard.

I clean mine up, and run it straight from the yard. My first one developed a leak on the input shaft after about 6 months. I ordered a rebuild kit for 45$ then came across another good Astro donor I pulled, cleaned up, and installed and working perfect. Now I have a spare and a rebuild kit on the shelf. They’re under 30$ in my yards. I am also running 99 to mid 2004-5 GM HD 2500 dual return Saginaw pump on a Wild horses bracket with some minor massaging of the return ports to get them out of the inner fender.

My local yard has a 2000 model Astro Van with the engine pulled and (2) 1998 models with the hydroboosts still in them. Said the 2000 doesn't have a motor and would be easiest to pull. Asked $75 for the booster, master cylinder, brake lines and proportioning valve. That a good deal?

 

[Tstinnett]

Not the desirable year. Angled bracket on the booster isn’t useable, angled master cylinder reservoirs. Brake lines will probably need to be custom regardless and I use the stock bronco proportion valve. I’d pass.
90-95 Astro has the flat bracket
Hydroboost 101 link here: https://classicbroncos.com/forums/showthread.php?t=131746&highlight=hydroboost+101

 

[ChrisR]

Thank you so much for the info! Saved me a lot of headaches!

 

[broncochevy]

Bracket

You may want to double check that master cylinder. 99-04 GM trucks were disc/disc and not disc/drum. After 05 many trucks went back to drums in the rear, but again there are a lot of variations.

I have seen quite a few of them in the yards on the XL, Denali and 2500 trucks. I’m curious if the bolt pattern on the mounting bracket is the same as the Astro? Astro donors are becoming more rare and I see many already pulled on my visits. How big a PITA was it to pull? I’ve got the Astro down to about 10 minutes in the yard.

I clean mine up, and run it straight from the yard. My first one developed a leak on the input shaft after about 6 months. I ordered a rebuild kit for 45$ then came across another good Astro donor I pulled, cleaned up, and installed and working perfect. Now I have a spare and a rebuild kit on the shelf. They’re under 30$ in my yards. I am also running 99 to mid 2004-5 GM HD 2500 dual return Saginaw pump on a Wild horses bracket with some minor massaging of the return ports to get them out of the inner fender.

The bracket is similar but I don’t think the same as the Astro, I will get a pic tonight and post. I do remember that the bolts are not configured in a square.

 

[broncochevy]

You may want to double check that master cylinder. 99-04 GM trucks were disc/disc and not disc/drum. After 05 many trucks went back to drums in the rear, but again there are a lot of variations.

I have seen quite a few of them in the yards on the XL, Denali and 2500 trucks. I’m curious if the bolt pattern on the mounting bracket is the same as the Astro? Astro donors are becoming more rare and I see many already pulled on my visits. How big a PITA was it to pull? I’ve got the Astro down to about 10 minutes in the yard.

I clean mine up, and run it straight from the yard. My first one developed a leak on the input shaft after about 6 months. I ordered a rebuild kit for 45$ then came across another good Astro donor I pulled, cleaned up, and installed and working perfect. Now I have a spare and a rebuild kit on the shelf. They’re under 30$ in my yards. I am also running 99 to mid 2004-5 GM HD 2500 dual return Saginaw pump on a Wild horses bracket with some minor massaging of the return ports to get them out of the inner fender.

And that’s a good point about the master cylinder. I wasn't really planning on using it, however if it works then so be it. I will have 4 wheel disc. The rear is installed with no brake hard lines with explorer discs, and the front will be the Chevy front disc swap, I have all parts except the spindle spacers and seals. Need to clean and paint first. I was actually getting some parts for that swap when I found the 2004 2500HD with hydroboost. Saw the pump and couldn’t pass it up.
I was under the impression a new bracket could be made to accommodate the bronco bolt holes if wanted. Is this true? I don’t see why I cannot make a bracket that uses existing holes in the firewall for the bolts and possibly scoot over the pushrod hole to move the booster closer to the fender well?? Maybe I’m missing something? I have seen guys cut and thread the pushrod, is it possible to make a bend or two in one, obviously making it strong by some means of reinforcement?

 

[Tstinnett]

Good info here:
https://classicbroncos.com/forums/showthread.php?t=257083
If you are looking to buy brackets this ebay store of a member here has some great options: https://www.ebay.com/str/earlybroncopartsstore

My hydroboost is cut and threaded with a clevis , running on the factory angled boost bracket. I would be careful with bending the input rod, there are seals on it and the stroke needs to be mostly linear or I would fear premature seal failure.

 

[broncochevy]

Thanks for the info. Learn something new every day