The first inch or so of my pedal is not the same as the rest. I assume there is some travel in the pedal required where the rod is not moving much, but I haven't gotten under the dash to look.
Did you see the part of the video where they showed pushing on the rod to remove the last bit of air that's trapped in the MC around the seals? I did that with vacuum applied also, and I did see small air bubbles come out of the system. Perhaps apply pressure and try just touching the pedal to engage that first bit of movement and watch for more air to escape?
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