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On my 79 when I push on the brakes the booster makes a noise which the easiest way to explain it is a farting noise. I have done the tests that I know of on it and it has passed all of the tests, pushing on the brakes then starting the engine and pedal goes down some etc. Could this booster still be defective causing my pedal to somewhat feel spongy?? I have seen elsewhere on the internet that a defective booster could make the pedal feel spongy but it did not come from a real reliable source. As much as I have bled the lines there is no way there is any air in the lines.
Sounds silly, but maybe lube the pivot points on the brake pedal? If the booster shows no other signs of an issue, you know there is no air int he lines...the pedal seems like a possible culprit.
To properly trouble shoot, if you hook a vacuum gauge to the supply and push pedal to 0 reading, then shut engine off, then hold at position, a kick back indicates vacuum leak. Good luck.
Well I went ahead and replaced the booster today. So now there is one less thing making farting noises in the truck and according to my wife that is a good thing!