Hi Bob,
Here's my .02 about your brake switch problem. Refer to your Shop Manual on
Page M.4. In addition to the larger fluid flow orfice, there is a very small
second hole in the bottom of the master cylinder reservoir that most people
overlook. I've read that its only .010" in diameter. The Manual identifies
it as a compensating orfice and its purpose is to equalize any pressure
caused by heat or whatever by allowing fluid to return to the reservoir. If
this fluid pressure is not allowed to equalize, it might cause a brake light
switch to remain in the closed or brake light on position.
The fix could be as simple as inserting a proper sized wire into the hole to
clear it. The hazard is that the wire could damage the rubber cup if it is
mispositioned in its bore. The safest way is to disassemble the MC and check
it. An inbetween method might be to gingerly probe the hole with the thin
wire and stop if you think you're hitting the rubber cup. You're faced with
the question, "am I hitting the cup or is it the rust/dirt obstruction?"
Good luck. Jim
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