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Discussion Starter · #1 ·
as for the pedal, it seems to be the same size as the factory one (length wise) from the bottom of the sleeve for the bolt to the top left edge of the brake pedal rubber is about 14 1/2" just like the oem one.

Brand new pedal from GM
Hoses used:
booster to rack
booster to pump
return line from booster to pump
Booster and master cylinder
 

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Discussion Starter · #2 ·
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unplug both of these harnesses. I just rolled them down and out of the way. I removed the whole sensor from the bottom (it was a simple removal)

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15mm ratchet wrench works great to remove the master cylinder
ziptie it out of the way so you can use both hands to remove the booster
 

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Discussion Starter · #3 ·
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remove the 8mm (5/16) bolt from the rack and pinion hoses. the top is the return from the cooler and the bottom (pictured) is the pressure hose.

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remove the entire hose from the truck. it is a 5/8" (16mm) wrench at the rear of the pump. as you can tell GM really screwed this hose and rack design up
 

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Discussion Starter · #4 ·
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loosen the 10mm bolt that holds the clip (it will not come out of the clip) you will then use a small flat head to pry the clip open and roll it out. the clip will then be able to be removed with ease.

you will need an 18mm ratchet wrench, a deep drive 18mm socket, 3" extension, 3/8" ratchet to remove the brake pedal.
photo5.jpg

factory vs 2500hd pedal
 

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Discussion Starter · #5 ·
photo2.jpg


15mm with a swivel, extension, cordless impact worked for me to remove the nuts for the booster. I did have to use a short ratchet to remove the top left nut though. I did not take pics of the removal.


I have installed the booster to pump hose, drilled the new hole, test fit the booster. I will have to trim a little out of the upper part of the hole due to the jam nut on the back of the booster not being "Flat" to allow the booster to sit flush. it's a simple task with a pencil grinder so I will deal with that tomorrow.


I will be going to the part store tomorrow to hopefully look at a master cylinder to see if the steel tubing will fit the booster I will need to order.
 

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Discussion Starter · #6 ·
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Everything installed. Just waiting on my master cylinder to come in now.

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You can see the hole in the bracket is close to the factory hole. So IF you wanted you can cut the bottom stud off, slot the bracket more and run a bolt with a flat washer combo.

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I moved the pump to booster hose off of the pump a little for safety
 

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Discussion Starter · #7 ·
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Simple splice. Should hold up just fine bc the hoses dont even have "wire cores"
 

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Discussion Starter · #8 ·
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Booster to Rack hose installed, return from booster to pump is installed. I need a 3/8" brass T to splice into the pump return.
Then all i will have left is:
master cylinder
change rotors and pads (decided to do new everything)
bleed the brakes
fill up the powersteering pump and bleed the air
 
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