I can't rule out a regular brake issue, so will continue to bleed.
Here is what I found doing some research. I found a bronco group doing this swap and they ran into problems with the return line being "T'ed" into the power steering return line. It can create a restriction sensation to the unit.
The solution is to plug a second line into the resevior (like the actual Chevy trucks do).
The test is to run the return line into a catch can. Start the car up and test the brake. If the pedal comes right up and it works, then I have to re-route the return. If no change...then I am going to consider again issues with the brake fluid/air and or a bad hydroboost unit (bought it used from the j/y).
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