Noise after new brake booster

[petegangies]

When you go back ask them where the booster was actually manufactured (COO=Country of Origin), if the shop doesn't know ask Hulk 4x4.

If you look at that one photo from the rear (taken off the website), hard to say for sure but the metal appears scratched and dented/gouged (right upper).

I can see what you're seeing and it's ordinary. They are apparently designed & engineered in Australia with full ADR compliance with ADR35 compliant brake test available for Engineers or Transport Authorities to sign off.

Not much I can do now though. I'll let them replace it and hopefully the new one has no issues, otherwise I'll have to insist on a different brand being installed.

 

[landtank]

I pulled my brake booster out of my 1995 with zero drama.

Simple, disconnect the pushrod from the brake pedal. Then remove the pushrod from the booster.

Without that pushrod being on the booster you have more ability to rotate and tilt the booster out of the truck.

 

[petegangies]

Update.. Hulk 4x4 have discontinued the booster fitted to my vehicle, and are in the process of redesigning a new range with no ETA. So I contacted my supplier who sold and installed it for me and let him know. He now wants me to pay extra to have a DBA booster installed.

My argument is that he is required under Australian Consumer Law to provide a warranty replacement of equal to or higher value and specification.

The only other options I can see are PDI, Bendix and Terrain Tamer, with PDI being the closest in price to the Hulk 4x4. He already stung me for a newer 4 bolt master cylinder to suit the Hulk 4x4 booster because he didn't realise mine was a 2-bolt, so I'm not paying any extra, again!

I think any of those 3 brands would probably be as good (or better) than the Hulk 4x4.

 

[AussieHJCruza]

The Terrain Tamer boosters are decent.

 

[petegangies]

The Terrain Tamer boosters are decent.

good to know!

 

[AussieHJCruza]

My former 60 series on Nitto 35" muddies (Truck weighed about 2800kg full of fuel) passed the pink slip brake tests with pretty similar pedal force to my wife's Subaru Forester with a terrain tamer 80 series booster, terrain tamer fortified brake pads and 75 series calipers.
Could lock the tyres up at will on dry asphalt at 100+

 

[Broski]

Guys, I appreciate that there is someone who has been able to do this without drama, but I have three trucks that absolutely cannot be disassembled this way.

When I say inches, I mean 4 inches of overlap. There is no way to move the engine far enough on any of these trucks to get the booster out. I have successfully removed one 1994 booster, without touching anything else in the engine compartment. That booster came straight off the firewall. I was shocked.

The truck was in a salvage yard, and I have that booster on my shelf. I know some trucks are setup this way, because I've seen one, but there are also trucks that are nightmares to get this part out of.

What motor do these trucks have ? That makes it so hard.

 

[Malleus]

They are all US models with 1FZ-FE engines.

 

[landtank]

I just stuck in an oem booster a few months ago.

Pro tip: take the pushrod off the back of the booster before removing or installing the booster. Doing so allows you to install/remove with no drama.

 

[ajax1]

I have done it a few time, as stated above pull push rod off, last one I did with it on, get the booster close to the intake about inch away,cock it to the driver fend er as much as possible, then I pop it with pry bar from the back side of the booster and it goes right pass the intake. This has been with oem boosters

 

[petegangies]

Dropped the car in this morning to the brake place that supplied and fitted the Hulk 4x4 booster. Hulk 4x4 have advised that their boosters are now discontinued, due to a known fault, with no ETA on a new model. Therefore, they have paid the brake place the balance to fit a brand new DBA booster, which I'm happy about as a suitable replacement. In fact, the DBA should be (by all rights), a better quality (and performing) booster.

Hopefully it's installed without a hitch and no damage done to the vehicle when removing and refitting the new one. Last time this workshop splashed brake fluid up the fender.. luckily I noticed it when I went to pick it up and flushed it with water—the apprentice then sprayed NIFTY on it and proceeded to use a dirty workshop rag to wipe it up.. It still required me to polish out streaks in the clear coat with my DA polisher that had been caused by the corrosive nature of the brake fluid. They'd also installed the pedal pin and spring the wrong way around and it was rubbing. Hopefully I never have to deal with this lot again after today.

Will update again on the performance of the dual diaphragm heavy duty DBA booster after I've had a chance to put it through its paces.

Cheers,
Pete