Proper adjustment of the master cylinder pushrod is necessary to ensure proper operation of the power brake system. A pushrod that is too long causes the master cylinder piston to close off the replenishing port, preventing hydraulic pressure from being released and resulting in brake drag. A pushrod that is too short causes excessive brake pedal travel and causes groaning noises to come from the booster when the brakes are applied. A properly adjusted pushrod that remains assembled to the booster with which it was matched during production should not require service adjustment. However, if the booster, master cylinder, or pushrod are replaced, the pushrod might require adjustment.

There are two methods that can be used to check for proper pushrod length and installation: the gauge method and the air method.

Gauge Method

In most vacuum power units, the master cylinder pushrod length is fixed, and length is usually checked only after the unit has been overhauled or replaced. A typical adjustment using the gauge method is shown below.

Gauge for measuring pushrod length. Courtesy of General Motors Corporation-Service Operations.

Air Method

The air testing method uses compressed air applied to the hydraulic outlet of the master cylinder. Air pressure is regulated to a value of approximately 5 psi (35 kPa) to prevent brake fluid spraying from the master cylinder. If air passes through the replenishing port, which is the smaller of the two holes in the bottom of the master cylinder reservoir, the adjustment is satisfactory. If air does not flow through the replenishing port, adjust the pushrod as required, either by means of the adjustment screw (if provided) or by adding shims between the master cylinder and power unit shell until the air flows freely.