Hi, this is a strange (and embarrassing) one that 2 indy garages and a ford garage cant seem to solve. 2016 S max tdci 180

TLDR; brakes don't react to emergency stop. Rears seem to be doing most of the work (based off brake dust and heat). Pedal wont physically go beyond halfway.
Replacement master cylinder and abs pump. Servo tested ok.

The longer version is that this started when I changed my discs and pads and changed a caliper at the same time because I activated the Ebrake release at the wrong moment (it was unbolted from the carrier) which caused a caliper to destroy itself. (an expensive mistake!) So I fitted a new genuine caliper, as well as discs and pads all around with no issues until it was bleeding time. The passenger rear and drivers front would only allow the pedal to go down halfway then stop solid, while the drivers rear and passenger front bled as normal (pedal to the floor). Fluid was still coming out as normal so assumed all was good. Took it for a drive and the pedal just went to the floor - turns out the master cylinder had blown too. Had this replaced which gave me a firm pedal under braking, but an emergency stop wasn't powerful enough to activate the ABS (almost like no servo assistance or the fronts weren't grabbing properly). I had a garage bleed my system, as well as an ABS bleed to double check, but still had underwhelming brakes, and a pedal that wouldn't go beyond halfway when pressed when stationary no matter how hard I try (similar to my bleeding issue). So I had a replacement ABS pump fitted in case the issue was somewhere within that. This gave me a normal spongier pedal and adequate progressive brakes, but if I suddenly slammed them on then barely anything happened, and after a few miles of driving the firm pedal returned and stopped me from pressing it beyond halfway when stationary, and unable to do a hard emergency stop. I've had the servo tested and its holding vacuum as normal. The fronts get warm but the rears sizzling after a few attempts at hard stops (but could be due to vented/non vented discs?)

At this stage I feel like it must be something simple, could I have a faulty caliper somewhere? Does the car think there's still a problem so is limiting my brakes? I've trawled every corner of the internet searching for an answer, and I feel like I'm an expert on brakes now, except for my own issue! Please send help if possible, Cheers.

 

Brakes need bleeding in service mode to be sure to get all the air bubbles out, FORScan can do this.

Just pumping the pedal isn't enough

Once bled, reset the park brake by:

Engine on

Foot hard on brake pedal

Park brake off

Press and hold park brake "OFF" button for 6 seconds

Keep foot on brake

Activate Park brake

Pull and hold Park brake "ON" for 6 seconds

Similar situation here, 2015 mk2 smax (yes, they only came out in 2016, mine was registered in Aug 2015).

Brakes seem harder to press to come to a stop, I have not tried an emergency stop yet, however back right is getting really hit, like smoking hot. 

 

I have swopped rear pads, no difference, rear discs, no difference. 

What I have noticed is the pads seem to grab the disc when I try rotate the wheel forwards, but release it when I rotate the wheel backwards. 

I notice rebuild kits come with an adjuster, maybe this is out somehow?