So HiHoeSilver was on the right track. It ended up that I pinched the large split teflon seal on the 2nd apply piston. The OE Split telfon seal that came off with the old servo was in really good condition, so I am re-using it until I can install the new seal next weekend. To keep the teflon seal from pinching, I really filled the seal groove with petroleum jelly before placing the seal in the groove. Install is much easier the 2nd time around.
Jeff, yes I did old pin was right under 1/8" and new one puts me a little over 1/16"
Now everything is working, and man it sure makes a difference!