Brake light switch at the brake pedal is suddenly 2-3mm short and won't reach the piece on the pedal that makes it cut off. Brake lights stay on all the time. When I test the switch with my finger, it works fine. I recently pulled out the master cylinder and booster to change out heater core hoses, but everything seemed to go back fine. Booster bolted up tight and I was able to connect the pedal normally without any issues, well except that it doesn't hit the brake switch.

I tried pulling backward on the brake pedal to see if the booster shaft would come out a little bit more, but it doesn't.

Pulling the switch plunger out doesn't do anything. It doesn't feel collapsed. What the hell? I cannot figure this out.

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2009 E320 Bluetec 117,000
1995 E300D 306,000 Sold
1996 Ford Taurus LX 130,000 Sold
1985 300TD Still 225,000 Sold
2016 Ford Fusion 24,900

I had my 17 year old daughter helping me bleed the brakes. Do you think she could have pumped the pedal too hard and bent something? Could the switch just be worn down? This is confounding, and that the switch is not adjustable is a real pain. I'll try a new switch, but if that doesn't work, I'm tapping a hole in the tab that activates the switch and making it adjustable.

__________________
2009 E320 Bluetec 117,000
1995 E300D 306,000 Sold
1996 Ford Taurus LX 130,000 Sold
1985 300TD Still 225,000 Sold
2016 Ford Fusion 24,900