G'evening everyone! I've got a '97 Ram that suddenly developed a leaking diaphram in the power brake booster. No problem, I pulled the old one out, took it into NAPA, and got myself a remanned OEM booster. Upon returning home and attempting to install it, I noticed that the piston (master cylinder pushrod) on the power booster was about an inch or two shorter than it was on the booster that I had just pulled off. A quick glance at the tag revealed the phrase "may need to be adjusted".

So, I decided to just get it all into place, bleed my brakes, and worry about adjustment afterwards. Bleeding the brakes revealed a leaking seal in my Dana 60. Replaced the seals on both sides, and now it's back to my braking troubles, albeit a few days later. So, now I have a new power booster, who's piston won't even tough the master cylinder until the pedal reaches about half way to the floor. Very little travel after the brakes engage, and there's almost NO brake power whatsoever.

Thank goodness I'm good at driving a manual and don't "technically" need my brakes to stop.

My question still remains, however. How do you adjust the default position of the power brake piston? (the piston that pushes into the master cylinder)?