A budy of mine suggested my push rod needs to be adjusted possibly? states i should have 1" of up travel on pedal...will look into that as well
Not sure that's a legit indicator here though. The pedal should come up all the way to where it stops naturally just from the spring pressure in both the master and the booster.
I could be wrong, as these booster setups do have some interesting characteristics.
But how does it feel when pushing on it?
Since you did not change anything with the master/booster setup and it worked before, maybe it's ok. Or maybe it was just ok with drum brakes but now that you have more powerful brakes (by a little bit anyway) and more consistent, perhaps a mis-adjustment is now rearing it's ugly head.
Any residual pressure check valves should be removed, but I've driven Broncos with them left in and they hardly even dragged. So a full lockup seems extreme just for a check valve.
But if you loosen the fitting at the master and it releases the pressure, you might be on to something.
Sounds like you ground enough, but when you look over the top of the tires down at the calipers, can you see daylight between them and the knuckles?
Which rear disc setup did you use? If it's the ones with the finicky parking brake, maybe it's causing some trouble even though they're not hooked up.
And when it comes right down to it, a poorly built prop valve can lock up the brakes. I don't know how, but I've seen it happen. Went through all the checks, and finally just changing to a new valve fixed it.
But that was after determining where in all the lines the pressure was being retained.
Good luck.
Paul
