LEAKING TPC HYDROBOOST

Hello friends,

I am chasing my next issue.   The TPC hydroboost leaks at the aluminum block where it mates to the side of the hydroboost.   I have replaced my o-ring (per Ray's legendary post) as I had the incorrect size originally.  However, the hydroboost continued to leak a small amount.   Last weekend I took the aluminum plate off one more time and installed yet another large o-ring along with a new copper crush washer.  It now leaks even worse.   I can actually see hydraulic fluid running down the bottom of that aluminum block and dripping onto my steering joints and headers.  I am confident both o-rings are seated properly and the large bolt is tight.   Had anyone else experienced this?  If so, do you have a solution you could recommend?

Thank you,
Aaron

Aaron,

I feel your pain!!  Unfortunately disassemble will be required again.

First...you CAN have an O-ring that is too big so you want to go back to the correct size.

Make sure the high pressure O-ring (the larger one) is a new Nitrile Rubber unit that is 7/8" OD / 11/16" ID x 3/32" thickness.

You will also need yet another new copper crush washer for the banjo bolt.

I suspect that a small piece of debris may have found its way into the O-ring seat or somewhere on the interface surface when you first replaced the incorrect O-ring.  You'll want to check for that after removing the oversized O-ring.  It is absolutely imperative that that all assembly components are spotless. This includes the mating surface on the HB itself.

While you have it all apart....take a good look at the aluminum adaptor and check for any abnormalities such as debris, scratches, gouges, or maybe even a crack.  Also make sure the mating surface is truly flat.

I hope one more go-around is all you need!!  Let us know how it goes.

My Hydroboost is leaking as well. I'm pretending that it doesn't for now.