I started with the Hydratech Hydroboost kit which came complete with everything needed for the basic installation. After reading many many threads about this install, I discovered a modification which runs the low pressure return line direct to the Power Steering Pump. This eliminates a 'T' fitting in the basic kit and prevents any fluid feedback to the HB unit. Parts for that mod were Tallon Hydraulics part# 8203 (5/16-24 O-ring male to -6AN male), 2-Russell 613161 90* -6AN hose ends, Russell 670850 -6AN Fuel Cell Bulkhead fitting, Tallon Hydraulics part# 1451 2pack of 3 Hole Hose Clamp Separators and Russell Stainless Steel braided low pressure hose. First drain the PS pump reservoir, remove old PS hoses from pump and steering box Then remove old master cylinder brake pedal rod from the brake pedal Disconnect the front and rear brake lines and remove the old master cylinder I made a new gasket to fit between the new HB unit and the firewall, I used Felpro# 3157 rubber fiber gasket material from NAPA Auto Parts. Then I installed the HB unit. Before installing the Wilwood master cylinder, install the two high pressure lines and the low pressure return line.

Super Chevy technical article on installing a hydroboost on a 1968 camaro. Booster, calipers, disc, etc., their car should stop on command. To compensate for the loss of vacuum, people. Aug 15, 2010  I started with the Hydratech Hydroboost kit which came complete with everything needed for the basic installation. After reading many many threads about this install, I discovered a modification which runs the low pressure return line direct to the Power Steering Pump.

Installation of these hoses is nearly impossible if you install the master cylinder first (ask me how I know). Remove the preinstalled brass 90* fitting for the low pressure return port from the HB unit, and replace with the THI 5/16'-24 O-ring male to -6AN male fitting on the HB unit. Be sure to torque ONLY to 10 ft. As the threads for this fitting can strip very easily.

Use one wrench to hold this fitting while tightening the Russell part# 613161 90* hose end with another wrench. Day 2) I drilled a hole above the fluid line in the PS pump reservoir and installed the Russell #670850 -6AN Fuel Cell bulkhead fitting in the reservoir for the low pressure return line from the HB unit. I stuffed a clean shop rag into the reservoir, spread some grease on the end of the drill bit(metal particles stick to it), and vacuumed real well with the shop vac to make sure no metal particles got into the reservoir. Then I cut to proper length, the two high pressure lines coming from the HB unit and installed the Aeroquip fittings and then installed them in their proper locations, and also installed the Russell part# 613161 90* hose end on the other end of the low pressure return line and installed that on the PS reservoir. Next, I need to fill the power steering pump with fluid, and bleed the system, checking for any possible leaks.

I'll be securing the two hose clamp separators to the inner fender, I need some new hardware for that. I also need to bend some new lines for installation of a proportioning valve and then bleed the brakes. Then a test drive!!

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