Replaced Brake Booster - now brake lights stay on -
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Unread 07-29-2005, 06:55 PM   #1
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Join Date: Mar 2005
Location: Chicago
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Replaced Brake Booster - now brake lights stay on

I finally tracked down my soft brakes and wandering idle to a brake booster leak. I replaced the booster and the master cylinder, trying to adjust the booster rod as best I could. The idle is smooth as could be now, the brakes are strong, but the brake lights now stay on. I've pulled the switch and it looks fine, it just looks like the brake pedal is staying down about 1/4" at the pedal, so it just doesn't quite press the switch far enough to turn off the lights.

Any ideas? Could this be related to the adjustable booster rod, and if it is, should I make the rod longer or shorter?? There doesn't seem to be any adjustment to the brake light switch (other than a little dab of epoxy on the top of the plunger to make it a little longer - my last option).

Thanks in advance!


'97 TJ, 4.0l, Auto, Mostly stock except:
ORF Sport Cage
31" Tires, 3.73 Gears
Rock Hard rear bar mounted low behind
rear seat for urban defense of my kids
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Unread 07-29-2005, 10:27 PM   #2
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Did you replace the booster with a stock vacuum booster?
You mention the adjustable booster rod, I'm sure that would be it. It's been a while since I've been under the dash, although I think you'll need to lengthen the adustment if you're looking to bring the pedal closer to you.

The brake switch is a very touchy, if it's barely off position at all, your brake lights will either be on all the time or never on at all.
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Last edited by rhinoss; 07-29-2005 at 11:45 PM..
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Unread 07-29-2005, 11:01 PM   #3
Stu Olson
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1998 TJ Wrangler 
Join Date: Oct 2004
Location: Arizona
Posts: 5,211
The brake switch has an adjustable plunger on it so that it can be adjusted for just this problem. If I remember correctly, the write-up on my hydroboost describes how this is done.
Stu Olson
ARB Locked & Loaded
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Unread 08-01-2005, 01:25 PM   #4
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Get a pair of wire cutters. Push the brake pedal down, using the wire cutters pull the brake light switch (the tab) all the way out. Let go of the brake pedal, it's self adjusting.
Vanco Power Brake Supply
9738 Atlantic Ave
South Gate, Ca 90280
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