Quote Originally Posted by Mr Smith View Post
The strange thing is, or at least it seams strange to me, when I start the car the vacuum will suck the pedal down about an inch on it's own. And when it isn't running I can lightly press on the pedal and it sounds like air is pumping then the pedal is stiffer.
Any ideas?
This statement "bugs" me! I think the weight of the pedal mechanism is closing the valve in the booster and causing the brakes to drag / be on.

A lot of people don't realize or don't know how a booster works but there is a equalization valve inside and I'm thinking your pedal assembly is closing that valve and giving you a headache.

I would add a spring temporarily to hold the pedal to the full off position and try again. I hope I'm wrong but it shouldn't hurt to try.