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I have a 2001 ram 3500 the hydro boost went out so I replaced the brake booster, and power steering pump. When I reinstalled the brake booster I bled everything and once I pushed the brake pedal it went to the floor, made a popping sound, stuck to the floor and drained all the fluid out of the weep hole. I have repeated this process 3 times with 2 different boosters and resealed one. I have absolutely no idea what’s going on or what I’m doing wrong. 

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Taking some things for granted (the pressure side is connected correctly and not swapped with the return)

It sounds like your input rod is too long, or the rear cover was removed and not reassembled properly, so the actuation lever is not in the correct position.  (never take for granted the input rod is the correct length out of the box!!!!!)

 

image.png.1c76975944293320b0be987c7e563e07.png

 

to determine if it is the input rod length, install it without connecting the input rod to the brake pedal.  start the truck.  The hydroboost should not go to full apply on its own.  You can try to push the input rod to see if it actuates and moves properly when not connected to the brake pedal.

 

GL

 

Hag

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