Just put in cluster and noticed brake pedal travel has increased.i know this can be adjusted at rod,but I had not touched it while rebuilding,pedal is firm when it finally connects.is it unusual to. Have to readjust rod.?is there a proper method gap?

Is the rubber pedal stop mounted on the cluster installed correctly?

Me thinks something changed. Check below; is your MC flush against the body. Is your cluster flush to the floor, also? No washers were added were they? It all sandwiches together.

mc is tight against firewall, ,cluster flush to floor,no added washers.maybe rod got loosend while i rebuilt cluster.

not sure what you mean by rubber pedal stop.ill look at it again tonite and check out the diagram.

just looked at pedal cluster diagram,and im missing the rubber stop piece .ill try that

I'm sure that will be your answer.
Pedal free play is measured from at rest on the stop to where the plunger contacts the m/c piston.

[quote name='Racer Chris' date='Jul 2 2014, 08:31 AM' post='2056740']
[quote name='rosenfe' post='2056733' date='Jul 2 2014, 10:11 AM']
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just looked at pedal cluster diagram,and im missing the rubber stop piece .ill try that
[/quote]
I'm sure that will be your answer.
Pedal free play is measured from at rest on the stop to where the plunger contacts the m/c piston.
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how much free play should there be?

The distance is something like a millimeter or so IIRC

That's the spec for the rod to piston clearance.
At the pedal its more like 1/2 to 3/4" I think.

ive decided that its not rod distance causing excessive pedal travel,but rather some air that needs to be bled.pedal does get firmer with less travel as i pump it.