No brakes in the morning. It will definitely wake you up more than coffee.

[xintersecty]

So lets say you fixed the mechanical side of things perfectly. Could there be a ABS failure that causing the brakes to loose power? For example the wheel sensor could be sending the wrong speed or the release valve is getting stuck. Does it even have ABS?

[jamesd]

No ABS, this is confirmed by the VIN# and no wires or sensors going to the wheels. This morning I took it to work and drove 13 miles in stop and go traffic. Everything works as it should, no hint of brake loss. I even slammed on the brakes a few times and it stops on a dime.. I did take a peek at the master cylinder for leaks or anything but on the brake booster I do see the black paint on it bubbling up around the area where the booster and master cylinder meet. Could that be from bench bleeding? I'm having it checked out again this morning. Very odd in deed. Somewhere I read about EGR valve could play role in this causing a vacuum leak. But no check engine light, no codes but... I do notice in the morning that the car seems to stumble a bit when starting up likes a losing power. But after the engine ran for a minute or two it levels out and works fine.

Side note: I'm not sure if this is important but I did have trouble finding a master cylinder for this car. Using the VIN# they came up with a part number for a master cylinder of GM 93742291 which is one with 10mm port valves. So did Autozone and O'Reilly. The one that was on the car was a 16mm port valve on there which I had to order from RockAuto since no one here carried it and GM had discontinued that part number. I ended up buying BECK/ARNLEY Part# 0729883.