OK, slow but sure. I have attached a few pics to document this. I cold not find this mentioned, so maybe it belongs in a sticky or something, or maybe it's just common knowledge, except when it comes to my knowledge.
Anyway, you do need to break open the old booster. I could see no other way to get that washer out (if someone knows differently, please chime in). Note of caution: There is plenty of left over oil inside this bad boy, so have something below that can get it all, or you will have a BIG oily mess on your hands. Also, both half's are under some spring pressure. I loosened and removed the 6 bolts, but the half's stuck together (rust and time). One light whack with a hammer and BAM, she came apart. Lucky I had the unit fairly secured or it would have been all over the place, along with afore mentioned oil.
Next, I removed the sprag washer and the push rod, spring and centering piece, which I now know is between the the master cylinder and the booster. Be gentle, but that washer will come out, just twist it side ways and pull it out. Another word of caution: Take note of how those pieces are siting in the booster before you disassemble. Those pieces sit a certain way and they need to go back in properly.
OK, as previous posts indicate, I had already installed the new booster and everything was assembled 100%. Since this is a PIA job, I was looking forward to taking everything back out to install this washer and pushrod. And guess what, you don't have to. As a matter of fact, it is my uneducated suggestion that when changing these out, go ahead and get everything buttoned up EXCEPT mounting the master cylinder to the booster. that said, this is my starting point.
Took my parts, went to the truck to put this together. Took off the master cylinder from the booster (two bolts and no mess). Got a 15/16 1/2" socket and a small extension. Mounted the pushrod and spring assembly into the booster. Then, I placed the sprag washer on the socket, then lined it all up in the mouth of the booster and gave it all a good push. It goes in easy enough, but you have to get it a good, forceful and steady push. One last word of caution (hey, what can I say): Make sure the pressure you apply to the washer as you are putting it in is even. DO NOT cock the washer or it could get stuck, which would really suck (picture taking it all apart, or even maybe trying to find another washer if the spring steel snaps!).
Anyway, just did the op test and all is right with the world again. I really appreciate everyones help and this site. Without either, a I am sure a local mechanic would have been glad to do it ($$$$$$$$$$$$$$$).
