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You might have trouble finding a 1/2 ton truck to use for an example. Hydroboost brakes were normally only supplied as OEM equipment on 1 ton trucks.
If you stay below 1987 the master should accept standard (SAE/"A") brake line fittings. You might not even have to change your current lines - but they may have to be reversed front to back. See the images below.
A cooler isn't necessary, but can easily be added later - if you find you need it.
As long as they are in good shape, your current brake lines will handle the pressure. The brake lines supplied with HB assist were identical to vacuum assist.
Couple of schematics:
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An 86 K20 with vacuum boost:
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And an 86 K30 with hydroboost:
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Where did you get that part number from? Google says it's for 1999-2011 vehicles. I looked at my hb pedal but there's no number on it. Figures, my old vac pedal has the number stamped on it plain as day but that doesn't do you any good.
Yep, the pin that the pushrod attaches to is in a different position. I thought changing the pedal was going to be a pain but it was much easier than I expected.
couldnt that pin on the pedal be cut and re welded at the appropriate position? Or cut and a small piece of round stuck be welded on? Also wonder about using a press to modify the shape of the pedal. Mor curious about the cutting and welded though
I've got a pedal assembly off a hydroboost that's going in my truck. I can check for a part # when I get home from work. The pedal came out of a '89 1 ton with the 465.