Again, pedal height retention test is for booster operation. All these test require that all air be removed from the hydraulic system PRIOR to conductiing tests, as mentioned on the "Hint" sections on BR-6 of the TSRM. The booster is not an issue until the hydraulic system is fixed and the tests can be performed correctly.
Agreed, reman'd parts are not always 100%. I went through two aftermarket power steering pumps before I had to use a new OEM Toyota pump to solve the problem. Same with other vehicles alternators and master cylinders.
And a crush washer kit from an auto parts store is a great way to go, agreed! Get twenty for the price of four.
Seeing as you now have decent pressure at the fronts and, as IJ said, there should be some wetness noticeable around the washers if there was a leak, especially if you pump up the brakes with the engine on and squish the living sh*t out of them, I would also agree and find it unlikely that the washers are giving up either.
It's been my expereince that new bleeders are only 50% effective at solving a caliper/bleed screw leak. If the caliper seat is damaged, new bleeders might not help.
The fact that the front have good pressure and the rears don't suggests either an internal master seal bypass issue or a leak (or air still trapped) somewhere in the rear. If the caliper seals are leaking, the fluid wont be immediately noticable as the dust seals should retain it for a while, and it is hard to see in there after the brakes are assembled. I have lost more than a few calipers because of internal pitting in the bore damaging the seals as they are pushed back during pad retraction for reassembly. Very common on twenty+year old brake calipers that have only operated in a limited range of travel for such a long time.
When we spoke on the phone, you mentioned you had a caliper that needed a little extra attention during the process, but I can't remeber which one. Was it one of the rears? If corrosion has attacked other parts of the caliper(s), then I would start my investigation there.
I always suspect calipers before masters as calipers see more heat, water, grime, etc. They live in a sh*tty environment. The master is babied by comparison. It sees fresh fluid first; the calipers rarely ever get this until a full system flush is completed. It sees very little heat, vibration, or any other damaging conditions relative to the calipers.
It's been my experience that masters only fail when: the system is neglected and the fluid turns to crap; The system is allowed to run dry and the seals swell from moisture absorption, then tear at first movement; excessive pedal travel moves the piston into a corroded (previously unused) portion of the piston bore, thereby damaging the seals (another reason not to use the pump-and-hold method of bleeding). There are other instances and ways to kill a master, but they are extremely rare.
My gut tells me it's probably a single caliper in the rear, or the master. But, again, if you have brakes after pumping, and the pedal remains firm (engine on, full operating pressure), then that would suggest the master is working, but it is having to compress the trapped air up to operating pressures before the brakes operate properly.
Air brakes are used on trucks and other vehicles. Air can be used, but Kenny, you are now the compressor, and have to pump the system up each time you want it to work.
As far as I am aware, there should be a brake proportioning valve that does restrict pressure to the rear calipers. This is also a fairly standard automotive practice, as far as I am aware. But the pressure should still be 1000+psi with vacuum assist, even at the rears. The fronts should be around 1500-1700psi w/vacuum.
Get a price on calipers while you are at Toyota.
Ahhh, screw it, Kenny....It's time for the Big Brake Kit! Guaranteed to make it all better!!!!!! Call Andy and FedEx!