Did you check the push rod adjustment from the pedal to the master cylinder and if you have a booster, from the booster to the master cylinder. If it is holding the master cylinder slightly depressed, maybe the fluid is moving internally. Just a guess.

 

Yeah I actually bought the tool to accurately measure and adjust pushrod. This really puzzling cause all I did was replace a sticking caliper.

 

I suspect the brake fluid all drained out of the master cylinder when you replaced the caliper
That means you need to re bleed the master cylinder first, then move on to the wheels
If you pumped it, that would send air to all 4 wheels
So, I'd start over with bleeding the system, master cylinder (again) first

 

Gonna get started on it again this week-going to install new distribution valve and bleed m/c on bench while off. Then do 4 wheel bleed and hopefully that will take care of it. I'll let you know. Thanks, Tom