I recently changed my brake booster to resolve an issue with weak brakes. The issue is fixed but I now have another problem...

The brake light switch's plunger will not reach the brake pedal arm anymore. There seems to be a .25" gap between the two. So my brake lights stay on at all times.

Did I install the wrong brake booster? I bought a used one from a recycler on eBay and I'm not sure which year Disco they pulled it out of.

 

Did you buy a new or used booster? If new where? If it was from Atlantic British then be aware that the list the wrong booster for the D2! I ordered a new booster from AB for my 2004 D2 and it was noticeably smaller (thinner) vs the booster I pulled from my truck. I called them and they sent me a second booster complete with a return label and that was was also thinner. Took a hour long conversation on the phone with them and a 3rd attempt for them to send me the correct replacement brake booster. Ill upload a picture later.

 

He bought a used one off ebay.

 

Yes I bought a used one. The cost difference is so much it didn't make sense to buy new.

Fwiw the one I put in looked visually the same as the original. I hope to tinker with it this weekend; hopefully I find an easy fix.

 

Why not put a piece of adhesive backed neoprene or some sort of shim on the brake pedal arm and call it a day.

I'm not hating on you buying it from ebay, those boosters are ridiculously priced, I was just clarifying!

 

not that you should have to do it, but the plunger is adjustable on the master side i believe.

 

Don't worry I never took offense to your post. I have actually thought of shim as well. I may just do that hah

 

Awesome.

The plunger was slightly loose in the booster; I believe I turned it thinking I was tightening it but I may have caused my current issue by doing so.

 

What did you mean by weak brakes?

 

Try this, remove your brake light switch, pull the plunger out (pull hard), push the brake pedal down, then re-install the brake light switch, let go of the brake pedal, and it should adjust itself. That should take care of your brake light issue.