This should be a no-brainer, but......

2003 ram 1500 5.7 hemi.

#7 exhaust spring failed. Removed brake booster with master cylinder to gain access to the spring

When I put the booster assembly back on the firewall and attach the rod to the brake pedal, the switch plate does not make contact with the switch. About 1/4 inch short. Brake lights stay on when battery is hooked up.

Its like I don't have the booster flush with the firewall. I have taken it on and off a few times. That's not it. The rod will not extend anymore. Unless there is a plastic tab that slides over the switch plate to take up the gap. But I did not see one and goes against logic in a brake assembly.

Any ideas?

Thanks

 

You probably bottomed out the switch. You can either replace the switch, or take it off, turn the square mounting flange back one click, pull out the plunger, re-install and twist back to lock it.