I removed the brake booster and the master cylinder to do the valve spring swap. When I bolted everything back together this evening and hooked it up to the brake pedal it's about a 1/4" from hitting the switch so my brake lights are always on. I haven't bled the lines or topped off the fluid yet could this cause the booster to not extend far enough to depress the switch? I just hate to go through the trouble of bleeding the MC and lines if I messed up something on the reinstall and I'll have to take it all apart to get it on right.

 

Make sure you centered the master cylinder on the center of the booster on the other side. Sometimes they can get crooked. Also make sure you seated the booster on the firewall properly. Other than that, they may have given you the wrong booster. You may have even unwittingly smashed your switch plunger down. You should be able to pull it out and reset it.

 

Well I know its the right booster, same one I removed, just needed it out of the way for the valve swap. I'll recheck alignment after work today.