Originally Posted by jamesrxx951
To remove the switch,rotate the stoplamp switch clockwise approximately one-eighth turn to remove the stoplamp switch. That switch is adjusted via the brake pedal. I believe if you pull out the center rod that presses against the pedal it will pull out some. It can take some effort. What happens is if you pull up on the pedal more than in normal travel the rod is pushed back into the switch even more. This will change the adjustment. Usually by pulling the rod out and then installing the switch back in when the pedal is pushed down will get it to readjust. I have had to replace some switches for that reason because I was not able to get it out. You may need to run to a local Autozone and get a switch. I believe it is the same switch as most modern Ford models.
Thanks for the diagram and the instructions. That's exactly what the switch looks like. I was able to pull the rod on the switch out, but it only disengages when the rod is almost all of the way in. I managed to get it working again by bending the metal tab on the pedal. I'll have to make it to a store to get a new switch.
While I was working on that, I figured out what is causing a nasty rattle when I hit a deep hole. I could duplicate the rattle by hitting the steering wheel hard on one side. It is actually caused by two things. One, the nylon bushing that goes between the booster's rod and the brake pedal is not a tight fit. It fits tightly against the pedal side, but loose on the booster's rod. That allows the pedal to have a little bit of back and forth play. The other one, and the main cause of the rattle, is the lateral movement on the entire pedal assembly. The pedal assembly rotates on a horizontally mounted bolt. There is a small gap between the assembly and the mount that needs to be shimmed.
Thanks for the reply. We'll see how it goes on the way down to GA from TN.