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Reply to "Excessive Brake Pedal Travel"

Rod length should not affect the stroke of the pedal, only change the position of the pedal, or create a certain amount of free pedal movement before it starts pushing the piston.
So, does the pedal have a low position before it starts to move?
Is it level with the clutch pedal?
If your pedal is starting at a high position & the pushrod is too short then the pedal will have no resistance for the first part of its stroke & then after a short amount of stroke you will start to feel pedal pressure.
If the pedal is high & the there is no slack in the pedal & there is pressure for the full stroke.
Then it could be the master cylinder bore is too small.
A small bore master cylinder will create a light pedal, requires little effort, but it will be a long stroke.
A larger master cylinder bore will do the opposite, it will be a hard pedal & have very little stroke & require more effort from the driver.
Regards,
Tony.
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