Thread: Brake troubles

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Keep in mind there is a difference in pressure & volume, If you unhooked the caliper and put a gauge on the front and back and got the same pressure (you did) that means that you still could have a volume issue or stuck piston, as of now you know that the fronts collapse at 600 psi and the rears don't, I still believe the easiest and no cost option would be to swap calipers on one side, those fronts could collapse at 600 psi as could the rears but the volume could be to much of a difference to ever get full pressure on the rear, it would also check your plumbing (valves, etc) if the rear don't collapse on the front rotor and the front does on the rear you now simply have a stuck piston or volume issue, and all else is kosher.
It doesn't mean your booster is bad either. A person can exert alot of force in a panic stop when his back is against the seat and he's using his legs, keep in mind that 99% of the time you don't exert full force on a brake pedal because you don't normally panic stop (normally), pedal leverage as Jerry said is mechanical advantage, as well as a smaller diameter master cylinder normally the pedal ratio is different for power brakes than non power.