I'm posting in here because I'm a former EG guy and I've always gotten a lot of help out of this forum. Anyway,

So I took my master cylinder back off and did a bunch of measuring.

Under vacuum, my brake booster pushrod extends an additional .150".

I measured the inside of my master cylinder, from flange to flange etc and did some math.

I need my booster pushrod to extend only ~1/4" from the inside booster flange under zero vacuum to have clearance on the master cylinder end.

I can get the pushrod to lengthen....but it won't retract any. It appears that I'm still 1/4" away from having the booster pushrod in far enough to not cause me master cylinder problems.

After a certain point, which still isn't far enough, the internal flange of the booster just starts backing itself into the booster.

It looks like this:



Am I screwed? Is there not a way to fix this? Does this mean that the brake booster rod is adjusted back as far as it can possibly go?
I need to be able to get this done using this brake booster. It's a 4+ hour job to remove it

For what it's worth, it's a '91 EX master cylinder with a '91 LX brake booster. I've had the setup before in a previous car and had no problems whatsoever.

I really need some help/ideas here! I've been having problems with my brakes sticking/dragging and I think I've finally narrowed it down to this.