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Check out the new m/c from Ram Man on the right, next to the one I pulled off the car. Is anyone familiar with the one on the left? Possibly a manual brake application? Needless to say the new one fits perfectly on the booster.
I can't find the original receipt, but my faint memory is telling me the unit was purchased from AZ or O'Reillys, instead of one of the quality Mopar vendors. Live and learn.
So, got the new m/c and a warranty replacement booster from Doctor Diff. (Cass is awesome, for those that didn't already know). Figured I'd get all fancy and bust out the calipers and measure the bore depth of the m/c vs. the pushrod length on the booster, minus 0.020". Spent way too much time dialing it all in.... and then on the bench, mocked up the m/c to the booster and could feel the piston engaging with the pushrod. WTF? It's simple math?!? Anyway, went old school. Applied a thin film of brake grease to the pushrod head, mocked it up and kept adjusting until there was no transfer to the piston bore. I think I'm ready to reinstall this weekend.