Got home Saturday night after a long day on the road, the last 3 hours at night.
Finally got to looking at the Cruise Control switches. They were plugged in. Really unhappy to see this:
Did a bit of reading. The CC pedal shutoff works through the brake light micro switch. Brake lights have to be on (or at least the plunger extended) to complete the disengagement circuit. Not only could I not disengage the cc with the brake pedal, I also did not have brake lights available for however long the white plunger was not extending.
PP does not have these 96461330100 in stock. Did find one online and should have it in about 10 days as its “special order” part. The switches Pelican has are the upgraded 96461330101 which look different but could surely be spliced in.
Removed the brake light switch. The plunger was definitely not working smoothly. Catching at any point in its travel just as it is in the pic above. I could tap it 5-6 times with a screwdriver then it would pop up and show continuity on the DVM. Finally figured nothing lost by taking it apart as it was useless as is.
Pried up a couple of the white tabs on the switch cap and it separated from the lower body. The plunger motion was course and dragging even with lots of spray lube. I played with it a bit and the plunder basically fell out.
Unfortunate I did not take a pic, but the white plastic plunger has a lip around the bottom to keep it attached to the lower body. The lip on mine was in poor shape, bent and missing part way around. I layed the plunger on a file a removed the ruined plastic lip.
Snapped it all back together and it works perfectly.
Put it back in the car. After checking the clutch pedal micro switch (it was ok) I went for a drive. Cruise control now disengages at a touch of the brake pedal. And I have reliable brake lights again, which is nice.
Should have caught it when I had the pedal cluster on the work bench a month ago.