The installation of a hydroboost system, specifically documented in the context of a Ford Bronco, involves adapting power steering components for brake assistance. The process, as detailed in the provided documentation, centers around sourcing appropriate lines, fittings, and adapting existing components to accommodate the hydroboost unit. The documentation outlines a largely DIY approach, including component cleaning, line fabrication, and bleeding the system. The project’s success relies on careful measurement, proper flaring techniques, and attention to potential leak points.
Component Sourcing and Cost
The documented installation required specific components, primarily brake lines and fittings, to connect the hydroboost unit to the power steering system and steering box. The following items were purchased for the project:
- Four lengths of 30" x 3/8" brake line at $5.23 each, totaling $20.93.
- Four lengths of 30" x 5/16" brake line at $4.86 each, totaling $19.44.
- Two brass unions, 3/8" size, at $2.09 each, totaling $4.18.
- One brass union, 5/16" size, at $2.29.
- One 90-degree 5/16" inverted flare to 1/8" pipe fitting at $1.89.
- One 90-degree 3/8" inverted flare to 1/8" brass fitting at $2.29.
- One package of 3/8" inverted flare nuts at $1.99.
- One brass 3/8" tee fitting at $5.16.
- One 5/16" threaded rod connecting nut at $0.49.
The total cost of these components was $58.66. The documentation notes that acquiring these parts was facilitated by an internal arrangement, resulting in no reimbursement required.
Hydroboost Unit Preparation and Inspection
Prior to installation, the hydroboost unit was disassembled and thoroughly cleaned to remove accumulated dirt. The unit’s master cylinder was described as being in average condition, while the power steering pump was noted to be in above-average condition. This suggests a salvage or used unit was employed, emphasizing the importance of inspection and cleaning before integration into the vehicle.
Installation Procedure: Line Fabrication
The installation process involved fabricating new hydraulic lines to connect the hydroboost unit to the power steering pump and steering box. The high-pressure (HP) line, originally present in the vehicle, was reused after being straightened, fitted with new nuts, and double-flared at both ends. The low-pressure (LP) line required more extensive work.
The LP line installation involved:
- Cutting the line to the required length.
- Performing double flaring on the connection intended for the steering box.
- Connecting the flared end to the steering box using a 3/8" union.
- Utilizing a tee fitting and 3/8" rubber line (originally used for fluid return) to complete the connection.
A separate fitting required welding. A 90-degree fitting was threaded into another fitting and then welded together. This was done to align the fitting correctly on the boost unit. Concerns were raised by a mechanic regarding the reliability of this welded joint, suggesting a brazed connection would be more secure. The mechanic ultimately brazed the fittings together.
Firewall Modification and Unit Mounting
Removal of the original vacuum boost unit revealed damage to the firewall bracing plate. The hydroboost unit required a 180-degree rotation for installation. The documentation notes that this orientation is not uncommon, even occurring in factory installations.
Bleeding the System and Initial Testing
Following the physical installation, the power steering pump was filled with fluid and allowed to circulate overnight to ensure complete system saturation. An initial check revealed a leak at the low-pressure fitting to the steering box, which was subsequently tightened. The system was then bled following shop manual instructions, involving jacking up the vehicle and supporting it on stands.
Consultation and Refinement
The installer consulted with Paul Clarke at Hydroboost, who provided helpful tips and confirmed the unit’s compatibility with the vehicle, despite its uncommon origin. Clarke indicated that a slight softness in the brake pedal feel was normal and would likely diminish with driving. He also expressed interest in the installation details and requested photographs.
Compatibility and Historical Context
Research indicated that Ford installed hydroboost units in certain Mercury vehicles, specifically large Mercury cars and some Mercury Monarch Ghias, between 1974 and 1979. The documentation highlights the relative obscurity of this application, noting that limited information existed regarding installations in vehicles other than those originally equipped with the system. Mechanics at the installer’s workplace confirmed that brake line, rather than high-pressure hose, was sufficient for the installation.
Additional Considerations
The documentation mentions a debate regarding the use of JB Weld for sealing brass fittings, with a mechanic strongly advising against it and advocating for brazing instead. This underscores the importance of using appropriate materials and techniques for hydraulic connections to prevent leaks and ensure system reliability.
Conclusion
The documented hydroboost installation on a Ford Bronco involved a significant amount of custom fabrication and adaptation of existing components. The project’s success hinged on careful planning, precise execution of flaring and fitting techniques, and attention to potential leak points. Consultation with experts and a thorough understanding of the system’s requirements were also crucial. The documentation highlights the potential for retrofitting hydroboost systems into vehicles not originally equipped with them, but emphasizes the need for a DIY approach and a willingness to address unforeseen challenges.