New Brake Master Cylinder issues!

[L_U_D_I_AAccord]

just like the title says New Brake Master Cylinder issues!
about a week ago i received my brand new brake master cylinder from TAS auto, after installation the brakes worked great, about a week latter now the brake pedal makes a strange noise. Now every time I hit the brake pedal it travels about an 2 inches or so and then I head loud "clunk" or "thump" noise.
It is not the release switch for the auto tranny lock.
It sound pretty hard, the brakes work good, even when the sound is there i don't see any difference in the way the car stops. This never happened with my old MC, I have bench bleed the MC, and after that the entire brake system to make sure I have fresh fluid.

[4thgentuner]

do u feel it n the pedal??

or does it sound like its coming from the caliper or sum'n

[L_U_D_I_AAccord]

yes, the feel is in the pedal
I had to rebuilt the driver side caliper because it was completely stuck
I did compress the caliper out, cleaned it and after that installed new seals

[BlackHaze]

Just replaced my master cylinder and have the same noise, but brakes work great. Any idea what this could be?

[HenRoc]

Bleed each corner. I'm assuming you bench bled the BMC before you installed it right?

[batever]

sounds like a mechanical impact after 2 inches of pedal travel. It could be the piston in the bmc bottoming out because of an improperly adjusted pushrod--the BMC could have come with one that wasn't set to spec (set too long). Other than that, i don't really know. Maybe your piston in your caliper is still sticking and that's stopping and causing the noise.

clarification: is the pedal stopping after 2 inches of travel (stopping with the "clunk") or is it continuing but you hear a clunk after 2 inches of travel but the pedal continues to travel?

other issues to double check are whether your BMC mounting nuts are actually all on there tight and whether the linkage from the pushrod to the brake pedal is kosher. Is the clevis pin that the pusrod pivots on (this is from memory) worn where it joins the pedal? Has the clevis pin pulled partially out so it's only going through one side? (if you forgot to put a cotter pin in the end of it ) Also, check to make sure your calipers are still mounted tightly. If there is play in the mounting, as the pad contacts the disc the caliper will shift as the disc tries to rotate it and that could be your clunking noise right there. Or the caliper could shift back away from the rotor until it meets the end of a mounting bolt and then that would cause the clunk. Although you said you think it's in the pedal, it's worth checking out.

[Losiracer2]

did you replace the caliper bracket with a new one? Is that why it was seizing up? or you just replaced the piston seals? Sometimes even if you clean the slide pins and bracket, the clearances afterward are too large and within no time, it can seize up again