I'm having the same issue with my 2000 Hyundai Elantra with no ABS. But, my master cylinder is still the original one and no one adjusted the rod length on mine (which seems to be the problem for the OP). Please see below and let me know your diagnosis.
The brakes are locking up intermittently in stop and go traffic for the last few months.
I removed the front tires. The brake pads were locked solid and the rotor wont rotate at all. Front-driver side brake and wheel was blistering hot, front-passenger side was less hot. Back brakes were not hot. When the wheel/brake lock up, the brake pedal is stuck at the up position, brake becomes super sensitive, the car drags and just touching the brake stops the car. Pressing with a lot of force wont make the brake pedal go down, it stays stuck at up position for 10 minutes even with the engine off.
15 minutes after turning the engine off, the brake pedal would go down a little bit. After 30 minutes everything becomes normal, the brake pedal goes down and up normally, the car drives normally afterwards for the rest of the day.
The car also runs louder than before. Rotating the steering wheel to the right diminishes the road noise partially.
People gave me a big list of things that could be causing this. After this locking issue started happening, over the last few months I replaced the following parts:
1. New brake pads and shoes on all 4 with new hardware.
2. New rubber brake hoses in both front brakes.
3. New wheel cylinders in both back brakes.
4. New caliper with piston assembly in front driver side. Passenger side is fine.
5. New wheel bearing in front driver side (there was visible smoke from front driver wheel when it first happened). Other bearings are fine.
6. New cheap Chinese tires on all 4.
7. Bled a large bottle of new brake fluid through the system.
None of the above fixed the problem and I am running out of $$ and ideas. Any ideas what may me be causing this intermittent brake locking issue?
Tuesday, December 5th, 2017 AT 12:55 AM