For years, I felt the brake pedal on my car traveled way too far. I replaced components, bled the system, and doubted every part of my work. It was suggested at the Fall Tech Session that I adjust the rod on the brake booster. After removing the master cylinder, and wedging a length of 2×4 between the brake pedal and my driver’s seat, the adjusting rod becomes exposed. While holding it with locking pliers, loosening it with some PB Blaster and an 8mm wrench, I was able to free it.
Here’s the adjusting rod removed:
I used increments of about 1/8 of an inch, to extend it, remount the master cylinder, and test the brake pedal travel. Finally I got to about 2 inches of travel before any brake pressure is felt. I used a little blue loctite on the threads once I found the sweet spot.
For the first time in many years, the brake pedal in the car feels very firm.