I started this thread because some others, as well as myself, have the impression that the SRT has too much brake pedal travel before braking begins. Anyone with any ideas on the subject is invited to add their thoughts. I think that should a seal fail suddenly there would be not enough travel to pump the brakes, having had a master cylinder fail suddenly when braking for a stopped bus I had to pump furiously and only just stopped in time. That was nearly sixty years ago and I remember it as if it was yesterday, a passenger who was about to get off using the rear exit of the London Transport bus saw the panic on my face and showed a similar expression on his own face. After getting off the bus he walked by me wiping his brow and laughing.
I had a similar experience in a rented car in Mexico in the middle of nowhere except for the resort we where going to, why did you drive by they said, I replied that the brakes did not work. It was a slow 50 mile return trip back to the car rental. The manager just shrugged when I told him there was no fluid in the reservoir.
I have had my SRT for 11 years and I have thought that the brake pedal travel was too much and had more travel than the NA I had before. I have replaced the Master Cylinder hoping it was the problem although I doubted it They are not spongy, they have no leaks anywhere and work well, I have changed the brake fluid three times in the nine years I have had the car and bled them at least twice between changes. The fluid was changed the third time last week. In all, I have run two litres of fluid through the brake system. The first time I changed the fluid I had my buddy help me and then twice I used the Goodridge self bleed nipples.
Last week I bled them with the engine stationary and then with the engine running, however, there was no change in the brake pedal travel.
The power brake systems are all basically the same, a diagram showing the basics is shown below. I used this diagram by Encyclopaedia Britannica because of the colours and component description, the one in the Crossfire Service Manual is poor.
You can see that with the engine not running the force felt at the pedal is provided by the spring in front of the brake booster piston. The spring is stronger than the atmospheric pressure on the back face of the piston, the difference between the spring and atmospheric pressure is provided by your foot pressure. The vacuum in front of the piston reduces the pressure needed. The different pressure needed from your foot on different cars would be due to the spring strength, the atmospheric pressure, piston diameters and the effective pedal length.
With the larger piston areas of the SRT callipers compared to the NA and because they use the same MC the travel required by the pedal will be more, how much more I cannot say. The calliper pistons move away from the rotor by only a few thousandths of an inch due to the seal lip returning to its no-pressure shape.
I shall continue after a short intermission.