Have you driven it?
I recall some of the disc brake stuff having a lot of caliper/caliper bracket stuff, or rotor, having enough flex to allow the pedal to travel deep when at a stop, but would work normally during driving...this might indicate a misalignment of the centering of the caliper on the rotor or in the mount? Caliper not moving?
Just a thought...

7381315-codger.gif (75 downloads)

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