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Old 03-16-2013, 10:50 PM
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So the pushrod to the pedal sounds like it is adjusted properly. Next, you need to check the pushrod between the booster and the master cylinder.

Remove the master cylinder (you don't usually need to remove the brake lines) and check to see if the small pushrod coming out of the booster is threaded and adjustable. If it is, lengthen it 2 or 3 turns and then slip the master cylinder back into position and see if you can feel the pushrod touching the master cylinder. If you can, shorten the pushrod 1 turn and try again. Just when you get to the point where the master cylinder will mate back up with the booster without touching the pushrod, shorten it 1/2 turn more and you are done. If it is a little out of adjustment it makes a big difference in pedal travel.
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