Finally found a Reman booster for my 93 D250 diesel. Have a fresh master cylinder now too. Comparing how much booster pushrod protrudes from the back of the booster versus the depth of the pushrod bore in the master using that same flange - No mention of any procedure in the service manual as to preferred clearance between the rod and piston.


Any experts out there on this and can you advice what clearance is called for?

.020" seems to be the accepted standard.

Thanks.

Surprised the service manual didn’t call this out.

Sounds about right. Too close, and there's a chance the brakes won't release when you let off the pedal, especially after they warm up.

Too far, and the pedal will be low due to the increased travel.

I made my own tool with three bolts and a threaded piece of 1/4" thick wood