Replacing the booster does not require special tools. The hydraulic system does not need to be opened or bled. They require no critical adjustments. Several hints and tricks will help you complete this job. The booster is a critical part of the braking system for the GMC so if you are not comfortable working on these components, take a copy of this article to your favorite repair facility.
Purchase the replacement booster unit before you start the job. The GMC booster is unique and you must get the correct unit. Sources are available at the end of this article. The two-inch push-rod between the peddle and the booster is unique to the GMC. Do not replace this push rod. They are not available from any source.
The
booster is found at the driver-side front-access door where you check
your
oil. See (A) on the photo. The booster attaches to the firewall
with
four bolts and the brake master cylinder (B) attaches to the booster
with
two bolts.
The master cylinder (B) can be unbolted from the booster and gently pulled forward toward the front grill. Do not remove the brake lines. The cylinder will move forward enough to be out of the way and not damage the attached brake lines.
The
four nuts
that hold the booster in place are inside the driving
compartment.
Later models of the GMC have a part of the plastic dashboard that
covers the area and hinders access to these nuts. The trick is to
cut out the bottom of this plastic enough to reach the nuts from the
bottom
of the dash. This plastic provides no structural support so no damage
is
done to the dashboard. The cutout cannot be seen from the front, and
you
will not have to remove the dash board. Be very careful that you
do not damage the plastic plunger assembly on the booster when you cut
out this plastic. I used a Dremmel tool with a router tip to make
the cutout. Even if you do not want to replace your
booster
now, it would be a good idea to make this modification so you can
replace
the booster on the road when it lets you down.
Disconnect the brake peddle and remove the booster out the front of the coach sliding it over the master cylinder. The new booster goes back in the same but reverse order.
The first time took me four hours. The second time would take less than two hours. I did not know how much of the plastic to remove, so I had to make several cuts. I will soon have a picture here to show the cutout.
Here is Arch's version on an older model GMC
http://www.gmcmhphotos.com/photos/brakes/p278.html
SUPPLIES
Booster
Dremmel tool
Flat ratchet wrench