Highlander, just for giggles you could hydraulically bypass the HydroVac and see how the manual system acts, it kinda' sounds like more than one problem. I ran my 2 ton for a few months with no HydroVac plumbed in, all new brake lines and hoses, rebuilt all 6 wheel cylinders and the master. When I rebuilt the HydroVac, everything came together and is working very well.
1957 Chevrolet 5700 LCF 283 SM420 2 speed rear, 1955 IH 300U T/A, 1978 Corvette 350 auto, 1978 Yamaha DT175, 1999 Harley Davidson Softail Fat Boy
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