well, after an exchange of emails with Mike Miller (Roundel Tech Ed), I bought brand new Master Cylinder and new TRW Booster. No adjustment necessary. They popped right in, I drive off, no brake dragging no locking up. I did have to bench bleed the master and the pedal is a tiny bit soft so I will drive it for a while then bleed again.


I measured the distance from the flange to the booster rod and the rebuilt one is about 1mm longer. That is all needed to lock up the brakes. The new one was 0.010 shorter than the old one, so that is the problem.


Tip: Don't buy a rebuilt one from Rock Auto. Mine is going back.