Brakes Front brakes heating up, pressurizing fluid, pedal stays up

I'm back fellas.... :/

Ok I have everything reassembled. The right side release now but still feels very tight and I actually think the rotor is warped from being cooked during the initial lock ups... the paint was cooked off. These were Stoptech blackhat slotted. I have some smooth steel ones in the box I will place on and this probably will resolve the issue.

But now Im stuck in the brake lights wont go off. I have taken the switch on and off, and even a new switch and still problems. I saw an old thread about someone saying they had the black bushing in wrong, Im wondering if it's worn out and too thin to keep the stop switch from activating? I'm at a loss on this one.

The end of the booster rod, the flat surface seems like there is more thickness to it than the factory one, which I have thrown away already. Its about a fat 1/4" of metal before the pin hole.

Thanks for any input.

Mike

Well yes and no. That picture is for a Cougar I read, so the switch actually goes with the open 'hook' end going down, not up, else the switch would be facing the firewall. I see LMR has a bushing kit, if the thickness was wore out then maybe it was cause it to be engaged all the time?

I can pull the pedal up all the way, doesnt turn off. If i take the switch off the pin the lights go out. It is such a tight squeeze to get it on and once i have it on the pin the lights come on.

I ordered this Cardone one from Rockauto, you had suggested this brand... check the photo. The rod has to be spun 180 to get to go on to the pedal, so it points down, else its too high. Thoughts?

Sure Ill take some pics tomorrow. My gut tells me the end of the rod just has too much metal thickness that just activated the switch when installed. I've rocked it etc. I dont have the inside bushing, because I have a black bracket slipped on the end that is the cruise control vacuum switch which acts like the spacer on the inside. I saw an older post where you were helping a user and he stated he had the black bushing in wrong and Im not sure how you can have that in wrong and it fixed his lights always on problem.

Here is me installing it again (10 times now, who designed this struggle at Ford? I wanna shoot him, lol).

You can tell its hard to get on, I have to force the brake pin through the switch which makes me think the end of the rod is too thick. I measured it with calipers, it's exactly a 1/16th thick. What is your old one?

Not sure what to do at this point. Could rig something up at the cruise vacuum switch area.

Full size image here...

Im wondering what that is right at the back side near the pedal rod that might be pulling the notched side back engaging it. I can tell what that is, maybe the part of the vacuum switch bracket that acts as the washer.


Mike

OK screw it, I took out the black spacer and it works as expected. Not sure it's long term solution but there is no play in the pedal and I can move on for now, my back is killing me! LOL. That tolerance must be tight and the end of my rod is just too thick I think.

Mike