Quote: I took off the master cylinder to see if the rod had backed down but it was still adjusted. pedal has more movement without the master bolted up, so no binding there, nor is it the booster.
It almost sounds like there isn't enough travel left in the master. Is it possible there is too much preload? Fully retracted the master piston should be very close to the mounting surface (bottomed against the c-clip). Mounting it to the booster should not compress the piston.
Likewise, is the booster fully retracted when the pedal is at its uppermost point?
