Could too much clearance cause this? Too little clearance. It will not allow the piston to return far enough to uncover the inlet from the reservoir. Bleed the master cylinder off the booster. When you are done and putting it back on the booster it should sit flush on the booster without any pressure to put it there. If the pushrod is holding it out then shorten the rod.
"Follow me the wise man said, but he walked behind"
'92 D250 Club Cab CTD, 47RH conversion, pump tweaks, injectors, rear disc and hydroboost conversion. '74 W200 Crew Cab 360, NV4500, D44, D60 and NP205 divorced transfer case. Rear disc and hydroboost conversion. 2019 1500 Long Horn Crew Cab 4WD, 5.7 Hemi.
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