With a gap of 0.250” and the pedal ratio 4:1, the brake pedal pad where you actually place your foot to stop will move an entire inch before anything happens. SIDEBAR - An example of an unfortunate experience: Imagine a gap of 0.250” between the pushrod at the booster and the back of the master cylinder. If the push rod depth is set too long, there will be a delay from the time your foot presses the brake pedal until the brakes engage, causing a soft brake pedal. Brake drag needs to be repaired as soon as possible, since it can force parts to overheat, damage the braking system, or cause an accident. On a manual brake system, you may experience brake drag, an uncomfortable feeling of the brake pedal not releasing as a result of the booster pin pushed up too closely against the master cylinder. If the booster pin depth is not properly set, you will notice several unpleasant symptoms while attempting to slow or stop your vehicle. We recommend the ideal depth of 0.020 inches. The booster pin depth should leave a small gap between the end of the pin and the master cylinder. The booster pin extends into a piston in the master cylinder to initiate the braking process. A brake booster pin, also known as a brake push rod, works as you press the brake pedal with your foot.
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