I had the same problem when I replaced my switch recently. I think the aftermarket switch is just a little bit shorter. I fixed the problem by gluing a piece of rubber to the end of the plunger. I pulled off the little rubber circles at the bottom of my cable box, glued them together, then glued that to the plunger. Two or three months and it's working great so far. I live in south Texas where it's hotter than hell, and the glue is still holding.

 

yeah right now i'm using pennies.

 

I have an aftermarket switch and had to pull it out with some force. Plunger clicked a few times when I pulled with force...This fixed the problem. Don't break it but it needs to click when the plunger moves out.

 

Did anyone find a soultion for this problem? I've got the same thing going on. Pedal is just 1/4" from switch. New booster.