Guys,

So I'm looking through old threads. Is there a preferred donor unit? I will get the assy w a mc.
I was looking on ebay and notice the new ac Delco stuff was made in china.
I know to make a steel adapter plate and shorten the pedal rod.
I can or will most likely have to make a hydraulic brake line.. and union up ps hoses.
Do the newer Delphi steering boxes from gen ii truck adapt easily to my d250? I see they made a quicker steering one.
Michael

 

in my opinion. the late 90s chevy van unit is the best for our trucks
Hydroboost conversion - Dodge Cummins Diesel Forum

 

I agree with Justin. The 95 and older Astro van unit is a direct drop in, at least the HB unit and firewall bracket. You can use the push rod, or make/buy a new one.

 

I did mine with an 04 superduty setup, all I did was add a spacer between it and the firewall. Pedal length etc worked well.

For brake lines one hooked up as is and the other I had to change the nut on..

I converted my hoses to jic and all those fittings (orb to jic) are available through earls and most likely Pegasus auto racing.

 

I converted my pressure hoses to AN-6 and made up a short 3/8" tube with a braze on end to feed my Reverse rotation steering gear.

OH and I used a pre 95 Astro van hydroboost with a 95 Chevy one ton master cylinder.

I also had to change one of the tube nuts on the master cylinder. the stock Dodge is 9/16-20 and the GM is 9/16-18.

 

I've been needing to do this swap for some time now (my stocker is leaking badly) just have not had time to get around to it. Looks like i went about getting parts the wrong way though. I sourced 2 hydros and a dual return port reservoir from 98-00 dodges.

 

more than one way to skin a cat. the only reason i ended up using the chevy van unit was by chance. i went to the junk yard to look for a late 2nd gen dodge unit. the one that was there was already gone. so i just started looking under hoods. I knew the astro vans had hydroboost but i hated the m/c on those and i just figured they were small and weak. when i stumbled across this g2500 fleet van and noticed that it had brakes comparable to our trucks and a bigger m/c, i snatched it up. the dodge one will work just fine though. i think thats what tcows used on his swap

 

Yea,

More than one way to skin a cat for sure. I was concerned with the astro van mc sizing and hb sizing as it's for a smaller vehicle. I was going to pnp the bracket off one.. and use it on a ford or chevy. The G2500 sounds like a good solution, but if I can get a newer unit - looks like the SD fords 2004 for example are ~ $99 booster + MC.
Then again- if I find one assy that looks good for $15 via pick n pull. It will probably get that one.

I think the dual return reservoir is a good thing. All those PS pumps appear to be Saginaw which only made 1 or 2 flow rates through all the years. I'm going to reseal the Vacuum pump and rebuild (seal + bushing) on the ps pump.

Thanks,

Michael

 

The stock astro van master cylinder is bigger than the stock Dodge at 1.25 but it has goofy reservoirs I got a M/C from a 94 3500 Chevy truck with a bigger reservoir.

 

the reservoirs is why i didn't like it, haha

 

I have seen guys run them with no problems. They just look funny to me.

 

I have had the dodge HB unit apart, and a HB unit from the Astro Van...same size piston and all basically. I would not hesitate to run one....in fact through all the trials and tribulations I had with my HB conversion I had enough parts leftover to rebuild a Astro van HB unit, complete with firewall bracket, and have it stashed in my spare parts selection. In case one day I build a Cummins Ramcharger....