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Old 08-10-2010, 08:36 PM   #7
sharp as a marble
Join Date: Jan 2007
Location: atlantic beach,florida
Posts: 1,085
Re: Brake pedal travel

the cheap diagnosis would be my ball of clay. IMO, you need to check the clearance between the booster and the master. What I do is to take a small ball of clay 1/4" in diameter, and put it on the rod that comes from the booster. Tighten up the master cylinder to the booster with the clay installed. DO NOT APPLY THE BRAKES! Then remove the master again. see if the clay is crushed? If it is not, then the rod coming from the booster needs to be longer. I have removed this rod, and welded a bead on the end, and rechecked. You only need a 1/16 or less between them. Danny had a BUNCH of free checks that will probably help.
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