Hydro boost brake conversion

[jjdeneen918]

Finally made some progress today.
I got the OEM brake booster out of the rig.
now to bring it to Power Brake Service.
I spoke to the owner last week, he requested I bring in my booster to look at since it’s been a long while since he put together a hydro booster together for an fzj80.

one helpful hint for removal that I hadn’t seen spoken of though:
Once everything is unbolted & your trying to wiggle it free. Take the rod (where the connector meets the brake pedal) -and shove it off the brake pedal. I put it to the inboard side of the pedal.
just one more area where things can get bound up while getting it free from the firewall.

 

[baldilocks]

Finally made some progress today.
I got the OEM brake booster out of the rig.
now to bring it to Power Brake Service.
I spoke to the owner last week, he requested I bring in my booster to look at since it’s been a long while since he put together a hydro booster together for an fzj80.

one helpful hint for removal that I hadn’t seen spoken of though:
Once everything is unbolted & your trying to wiggle it free. Take the rod (where the connector meets the brake pedal) -and shove it off the brake pedal. I put it to the inboard side of the pedal.
just one more area where things can get bound up while getting it free from the firewall.

He just put my kit together a few months ago. It seems strange he wants to see your booster because he took the company over from his father, so many years of data has been collected and logged.

 

[jjdeneen918]

Yeah, seemed odd, but that’s what he asked for.
He asked me to measure what the lengths need to be for the HP hoses.
Do you happen to know the lengths of your hoses Baldilocks?
It’ll save me a trip back to my cruiser that’s now sitting at my parents house. Not super local to me at the moment.

 

[baldilocks]

Yeah, seemed odd, but that’s what he asked for.
He asked me to measure what the lengths need to be for the HP hoses.
Do you happen to know the lengths of your hoses Baldilocks?
It’ll save me a trip back to my cruiser that’s now sitting at my parents house. Not super local to me at the moment.

Again a strange request. If he sends you 6’ of high pressure hose you will be good with some left over.

 

[cme4lyt]

I text’d with Matt yesterday and he said he’s shipping my kit next week. Hopefully all goes well since the anticipation is killing me !

 

[jjdeneen918]

I text’d with Matt yesterday and he said he’s shipping my kit next week. Hopefully all goes well since the anticipation is killing me !

who is Matt? I spoke with Bob. He said he is the owner. He mentioned is son hasthe access to their website,, but he’s running the business from his Facebook website.

https://m.facebook.com/pg/POWER-BRAKE-SERVICE-CO-122432777774021/about/

 

[baldilocks]

who is Matt? I spoke with Bob. He said he is the owner. He mentioned is son hasthe access to their website,, but he’s running the business from his Facebook website.

https://m.facebook.com/pg/POWER-BRAKE-SERVICE-CO-122432777774021/about/

You have been talking to the wrong people. Matt Sweeting's SPEED Manufacturing- Bosch Hydro-Boost, Bosch Hydro-Max, Vacuum, and Air/Hyrdaulic Power Brake Systems

 

[jjdeneen918]

Bob Sweeting is the name I spoke to.
It’s the same last name.
I find it hard to imagine it’s not all the same, unless there was some falling out & they split ways.

 

[baldilocks]

Bob Sweeting is the name I spoke to.
It’s the same last name.
I find it hard to imagine it’s not all the same, unless there was some falling out & they split ways.
View attachment 2228133

I don’t do business on FB so I don’t know. Use the link I posted and contact Matt Sweeting.

 

[jjdeneen918]

I dropped off my booster to Bob last night, so I feel I’m committed. This was the business card he gave me.

 

[jjdeneen918]

I made some more progress this week.

I rebuilt & re-installed the power steering pump using the rebuild kit from @NLXTACY @WitsEnd.

Everything went smoothly. One thing I didn't see mentioned anywhere was the location of the nuts location that need to be removed to slide the PS pump from the engine.

there are two bolts holding the PS pump to the engine. The bolts are not removed to pull the pump.
there are two nuts located on the back side of the pump. Once the 2 nuts are removed, the pump will slide backwards & off the engine.

The nuts are exactly 180-degrees opposite of each other. If your under the rig & look up at the back side of the pump, the two nuts are located at about the 2 & 8-o’clock positions.

the lower nut at 7-8-o’clock is visible from underneath the rig. The 2-ish o’clock nut is more hidden, but if you feel up in that area, it is there.

one more bit of advice. I used some grease to hold the large orange o-ring that seals the pump. It helps keep the o-ring in place & not move, fall, or shift around while placing the pump into position.

now I’m waiting on a bracket for my Appleton aftermarket PS reservoir, hydraulic brake booster, & the high pressure hoses to arrive.

I’ll update as I make more progress.

 

[baldilocks]

Nutz! Hold s*** together..

 

[jjdeneen918]

Oh, along with the power steering pump install, I also got @NLXTACY PS cooler & hose kit installed!

the kit is very comprehensive. It came with the drill bit & tap to make the install holes for the cooler.

I was only able to install 3 of the 4 bolts for the install. I have a bracket, welded in place, that is holding my Federal Signal electronic air horn & PA speaker. It prevented me from drilling the upper passenger side bolt hole.

I intend on having a friend plasma cutting a rock guard to install right under the cooler.
just a little extra protection in case I come down onto a rock in just the wrong spot.

that plate protection will essentially be a small shelf coming off the front cross member to protect the cooler.

in the event any of the bolts came off, that plate would prevent the cooler from falling into harms way.

totally unnecessary I’m sure. But peace of mind & overly engineered, just in case.

 

[jjdeneen918]

I got around to taking a few pictures of the things I got installed over the week. Everybody likes pictures.

Low pressure hoses going to & returning from the aftermarket cooler:

Aftermarket cooler replaced OEM paper-clip style cooler:

ower steering reservoir bracket, for the Appleton reservoir is complete. Item is currently on its way to the house, it’ll be installed shortly.

Reservoir & bracket:

Now I’m waiting on the hydraulic booster, new master cylindar, high pressure hoses, & all new SS brake hoses.

 

[jjdeneen918]

Made progress today.

Painted reservoir bracket
Installed bracket & Appleton reservoir.
Installed AN push-lock fittings onto low pressure lines & bolted to reservoir.

Before:

After:

 

[jjdeneen918]

I want to thank @NLXTACY @WitsEnd
For helping me with the reservoir bracket.

The bracket came out perfect. It looks great, super stout, & installed effortlessly.

Thank you Joey!

 

[NLXTACY]

No worries. Nothing like a pandemic to free up time

 

[jjdeneen918]

I FINALLY got my parts yesterday from Power Brake Service. I’m going to assume the COVID caused the delay in getting my parts to me.

@baldilocks I see there is a feed or bleed-off line From the hydro booster. It allows hydraulic fluid to return to the reservoir.

there was hose & a T-fitting provided. Can you explain or post a pic of where you spliced that into your low pressure lines?

Also, did you delete the return line for the LSPV line, going back to the MC?

@NLXTACY of my low pressure lines that are provided by you with the push lock fittings & Continental hose. Do you stock push lock T-fittings, so I can keep everything consistent?
Or a link to where I could source that fitting?

I’m also going to need to source adapter fittings to tie in the Toyota brake lines into the GM master cylinder. Female metric side to male GM side. If not, I’ll have to cut Toyota line flares, put on GM fitting & re-flare. I only have the ability to do a single, not double flare, but I think that should still work?

Waiting to hear from Power Brake Service for an adapter fitting, for the banjo fitting, to attach HP hose to the power steering pump.

I’m looking forward to start installing tomorrow afternoon.

 

[jjdeneen918]

 

[NLXTACY]

i'll look