If there's no pics...it didn't happen...

 

Got mine almost done guys, thank you for the valuable info posted here.
I used a 1998 g3500 express Chevy van hydro unit I didn't have to modifie the unit it was a direct bolt on and was clocked correctly. I have a 1990 D 350 truck.

 

Congrats....you'll love the new braking system!

 

Looks good

 

So here is a list of the items purchased to complete the upgrade to hydro boost brakes: I didn't have to cut and thread the arm to the brake arm the only thing that I will have to do there is to find / make a bushing for the hole because its a little larger than the original. the original master cylinder brake lines threaded right into the master cylinder.


WISH I WOULD HAVE SEEN THIS SITE EARLIER HERE IS A LINK TO THE SPRING & MASTER CYLINDER PUSH ROD THI 27288 - Power Piston Return Spring [THI 27288] - $25.00 : Tallon Hydraulics, Your Machine Shop!

1) 1998 chevy express van 3500 hydro boost
2) 1998 chevy express van 3500 master cylinder
3) 1998 dodge ram 3500 power steering pump with both return lines
4) 1994 thru 2000 dodge ram rotary style vacuum pump
5) 4 of these Aeroquip FBM FCM 1389 Steel Reusable Hose End -6 AN to 9/16 -18" Female 90deg
6) 1994 dodge ram power steering pump support bracket
7) master cylinder push rod, spring & retainer clip
8) hose for the power steering connectors

 

I did mine pretty close to what you did. the only difference was I did a R/R steering gear conversion. I'll post up my parts list later. Thanks for posting your parts list.

 

Thank you, I only bought this truck about 4 month ago and this update of the braking system was caused by a brake failure in the rear, (almost rear ending someone on the freeway) and not being able to stop the truck. so I went and bought all the parts to fix the truck, and two weeks later and 4 vacuum booster set up later I was still having problems with leaking master cylinders and bad vacuum booster. So I started googling fixes for this truck and ran across this post and decided it would be the best fix for my truck. This still remains to be seen because I still haven't drove it yet but I am sure this will work just fine. I am still waiting for some fitting to complete my install. But I am very interested in you steering box conversion.

 

you will be pleased. very similar to my setup.
Hydroboost conversion - Dodge Cummins Diesel Forum

 

Here is how NJT did his. nice write up. The perssure line from the hydroboost will have to be different though.
https://www.dieseltruckresource.com/...y-92-a-301769/

In post 922 of my build thread is how I got around the fitting clearance problem at the steering gear.
https://www.dieseltruckresource.com/...314771/page62/
some more of the 3/8" tube I made up I post 904 https://www.dieseltruckresource.com/...314771/page61/
and the braze on fitting
Aeroquip Steel Weld-In Bungs FBM2872 - Free Shipping on Orders Over $99 at Summit Racing

this only applies t the W250 4X4 trucks.

 

May as well post up my list for the fittings.

these two on the booster. they will only go one way.
Earl's Performance AN to Metric Adapter Fittings 961955ERL - Free Shipping on Orders Over $99 at Summit Racing
Earl's Performance AN to Metric Adapter Fittings 961956ERL - Free Shipping on Orders Over $99 at Summit Racing

this is the pressure fitting I used at the pump. BUT I changed the valve housing to the old inverted flare fitting.
Aeroquip Reusable Hose Ends FBM1382 - Free Shipping on Orders Over $99 at Summit Racing

I think this fitting combonation would work if you don't want to change the valve.
Earl's Performance AN to Metric Adapter Fittings 961956ERL - Free Shipping on Orders Over $99 at Summit Racing
Aeroquip Reusable Hose Ends FBM1386 - Free Shipping on Orders Over $99 at Summit Racing

two of these on the booster adapters.
Aeroquip Reusable Hose Ends FBM1389 - Free Shipping on Orders Over $99 at Summit Racing

this is the key to the Reverse rotation gear working with the hydroboost.
http://www.summitracing.com/parts/aer-fbm2872 this and this hose end.
Aeroquip Reusable Hose Ends FBM1386 - Free Shipping on Orders Over $99 at Summit Racing.

with this hose.
http://www.summitracing.com/parts/aer-fcg0606
they should also have it in black.

And some pictures of the pressure line for the R/R steering gear. I made a brace to the frame at the hose end to support that end.
Now that that is clear as mud more pictures in my build thread in my sigtature.

 

I apologize if this is a common newer unit design, but I don't think I have ever seen a hydro-boost with that fitting on the front of the boss for the low pressure return port. What is that?

The bracket from that '98 express van is really sweet, it pushes the unit away from the firewall just enough so that the stock GM pushrod will work. I might have to find me one to have as an option for the future. Thanks for the information!

 

How does the hole on the GM 3500 express van fit on the stud on the brake pedal? Is it dead on or too big and needs a bushing? I saw the pic further up in the post but couldn't really tell.

 

If I'm not mistaken that port is a screw in clear sight glass for what used to be a plug with a snap ring?

 

I think the one you are thinking of is to the left of the one in question.
this is the first one I have seen with the two ports.

 

Not an exact fit it will need to have a bushing installed.