The manager at the local Pep Boys (surprisingly sharp) explained that I was
sequencing the bleed incorrectly. I've been having my pusher, push the
pedal to the floor and "hold". Then bleed - stop - tighten and release
pedal. Repeat.

According to Steve, it should have been:


1. Crack bleed valve.
2. Push pedal down slowly and steadily while fluid exists the drain tube
into the bottle.
3. When Pedal is at the bottom, shut the bleeder and release.
4. REPEAT.

Can this small difference made a difference.

Also, he was a little skeptical that pushing on the brakes pedal during the
bleed process would under normal circumstances cause the Mater Cylinder
seals to rupture or deform.

Bob Franklin