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Did you ever figure out what was going on? I'm having similiar symptoms. Mine are on cylinders 3 and 7.

Had one in the shop yesterday with the same complaint. The front pads were seized to the brackets. Cleaned everything up and pedal was normal again. When the pads seized the caliper was flexing the pad to make it touch, and when it you would let off it pushed he pistons back in pretty far.

I have an 01 Ex for a very similar swap. Still waiting to come across a donor 6.4. Good luck on yours!