New brake booster failure?

Tiny
DLMECHANIC
  • MEMBER
  • 1998 CHEVROLET SILVERADO
  • 5.7L
  • V8
  • 4WD
  • AUTOMATIC
  • 160,000 MILES
I replaced the brake booster, which had been losing vacuum, and, even after shimming the rod to properly meet the master cylinder, the pedal travels much farther than it should. The brake engagement is poor. After a few miles of city driving the brakes get quite hot and begin to drag. With the front end in the air (when cool) I made sure that there was no drag in the brakes. I meticulously measured the space between the master's piston and the end of the booster rod and made sure I was shimmed in spec. I tested for pedal travel distance before fluid could be seen surging in the reservoir. Everything seems to check out. I never opened the hydraulic end of the system. What are the odds that the master went bad right when I changed the booster? A bad booster can't make the pedal travel too far and the brake performance poor, right?
Tuesday, September 19th, 2023 AT 11:13 AM

5 Replies

Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
  • 47,256 POSTS
Yep! It sounds like you got a defective brake booster that is not returning completely and causes the brake to stick on and get hot. Here is the correct way to replace the booster in case you need it.

Booster Mounting Nuts. 36 Nm (26 ft. Lbs.)

Check out the images (below). Please let us know what happens.
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Thursday, September 21st, 2023 AT 9:33 AM
Tiny
DLMECHANIC
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I'm not understanding how that accounts for the extra pedal travel though.
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Thursday, September 21st, 2023 AT 10:55 AM
Tiny
KEN L
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Does it feel like the pedal is loose or does it seem like it is working but with no pedal? Have you bled the system? please go over this guide:

https://www.2carpros.com/articles/brake-pedal-goes-to-the-floor

Please go over this guide and get back to us.
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Saturday, September 23rd, 2023 AT 10:28 AM
Tiny
DLMECHANIC
  • MEMBER
  • 3 POSTS
The pedal feels spongier than normal chevy brakes and travels further. The brakes will stop the vehicle but will not lock up or stop quickly. As I never opened anything on the hydraulic part of the system, I didn't bleed the brakes. I've checked for leaks and the master remains full. It worked normally before changing the vacuum booster so logic says that is the culprit, but I can't make sense of why.
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Saturday, September 23rd, 2023 AT 11:12 AM
Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
  • 47,256 POSTS
Yep, the brake booster sounds bad. They have a valve mechanism inside they must not be working correctly.
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Sunday, September 24th, 2023 AT 10:15 AM

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