One thing caught my eye that I overlooked earlier. You said you plugged both ports at the master cylinder, then the brake pedal "only" went down half way. That is absolutely no good. You know it can only go lower when there needs to be enough fluid volume to work the calipers and wheel cylinders. With both ports plugged, the pedal should go just far enough for the lip seals to run past the fluid return ports going to the reservoir. The pedal should be very high and hard, and only travel about two inches.
Is it possible you have a brake pedal assembly that was meant for use with non-power-brakes? That will have a different leverage ratio to make the pedal easier to push, but it will require a longer travel.
Monday, February 13th, 2017 AT 10:25 AM