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1999- 2500 Express work van, 5.7 L. Brake problem....
Found fluid leaking between master sylinder & hydraulic booster. Power steering fluid was very low. Brake very spongy and brake light comes on when depressed all the way to the floor. The master cylinder is new and bled well. Will this be solved by replacing the booster assembly? Is it necessary to remove the booster mounting plate from behind the dash, or can I just replace the front portion of the booster booster body by removing the from the four bolts? Help is very much appreciated.

Submitted: 77 days and 4 hours ago.

Category: Chevy

Value: $15

Status: AWAITING CUSTOMER ACTION

Year : 1999
Make : Chevrolet
Model : Express 2500
Engine : 5.7 L

Already Tried:
Replaced master cylinder before realizing the leak between cylinder and hydraulic booster was power steering fluid.

Posted by Delsley 77 days and 4 hours ago.

Answer

Hi XXXXXX... When you bled the master cylinder you would have to of bled the lines also if not it will cause the light to come one and cause it to have a soft pedal from air in the line.

77 days and 4 hours ago.

Reply

The entire brake system was bled for over an hour using almost 2 quarts of brake fluid. Can you anwer the remaining question? The fluid that was leaking was power steeting fluid coming from the hydraulic brake booster.

Posted by BigBlock434 77 days and 4 hours ago.

Answer

This one is very simple, remove master cylinder from hydraulic booster. Leave brake lines attached. Remove hydraulic lines from booster. Go inside look under dash and locate brake light switch(hooked to shaft of brake booster). Remove switch and look at the firewall and notice four 15MM nuts in a square form. Remove nuts and remove booster from under hood. Would be a good idea to replace all other fluid in power steering system and yes this will fix your other problem as well. Need anything else please ask.

Edited by BigBlock434 on 9/6/2009 at 12:58 AM

77 days and 3 hours ago.

Reply

BigBlock434, is the hydraulic booster seal inside the housing of the push rod to the master cylinder? Is rebuild kit available for the booster. And finally, have you heard of this problem with the booster causing this spongy feeling brake when engine is running? Much thanks for your help.

Accepted Answer

Yes seal is in there, but you can't rebuild it. Also when you replace hydraulic booster make sure you remove the drive rod from old booster and install in new one. Yes it is like any other hydraulic system you induce air and you get a spongy feeling.

Accepts:
Expert:	BigBlock434
Pos. Feedback:	97.1 %
Answered:	9/6/2009

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Optional Information

Year : 1999Make : ChevroletModel : Express 2500Engine : 5.7 L Already Tried: Replaced master cylinder before realizing the leak between cylinder and hydraulic booster was power steering fluid.

Answer

Hi XXXXXX... When you bled the master cylinder you would have to of bled the lines also if not it will cause the light to come one and cause it to have a soft pedal from air in the line.

Reply

The entire brake system was bled for over an hour using almost 2 quarts of brake fluid. Can you anwer the remaining question? The fluid that was leaking was power steeting fluid coming from the hydraulic brake booster.

Answer

Reply

BigBlock434, is the hydraulic booster seal inside the housing of the push rod to the master cylinder? Is rebuild kit available for the booster. And finally, have you heard of this problem with the booster causing this spongy feeling brake when engine is running? Much thanks for your help.

Accepted Answer

Yes seal is in there, but you can't rebuild it. Also when you replace hydraulic booster make sure you remove the drive rod from old booster and install in new one. Yes it is like any other hydraulic system you induce air and you get a spongy feeling.

Related Chevy Questions

Year : 1999
Make : Chevrolet
Model : Express 2500
Engine : 5.7 L

Already Tried:
Replaced master cylinder before realizing the leak between cylinder and hydraulic booster was power steering fluid.