Well, the plunger pushes into the booster/master cylinder for assembly. I know on the manual MC the pushrod is held in place with a rubber grommet type thing, and if you pull back on the pedal with your hand, it is pulling out enough that the rubber part is holding the rod back from the seat. Then when you push on it, the rubber let's of go back onto place, and it makes a noise when the rod seats in place. Normally you never notice this because the springs move it for you, and they don't pull the plunger out of place because the pedal stops before it pulls out. The pedal travel seems to be limited by the brake light switch, so once you have that adjusted properly, it won't do this anymore.
1978 CJ5 5.0HO/T177/D300, '86 D30/D44 WT axles, 'glass body, 31x10.5 BFG A/T, TDK galv'd frame - DD and weekend toy
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