The A40 braking system is the same as the A70 Hampshire, and A90 A90 Atlantic convertible, and it is essential to ensure that the brake shoe mechanical adjustments been undertaken to ensure that the shoe travel is not excessive.
This also applies to the pedal movement, for if this is not fully out when released, it may not be allowing fluid to flow through the non pressurized compartment into the pressurizing side. For the special washer and the internal seal, such can only be replaced with the removal of the screwed cap.
If the piston assembly is not fully returning to the released position when the pedal is fully out, a few mm from the end of the piston, there are two holes on opposite sides of the piston, and with the piston fully released, these holes automatically align with the rear edge of the internal seal to allow flow to pass through the special washer into a small recess in the back of the inter diameter of the seal, aligning with the two holes, that allow fluid into the compression chamber of the master cylinder. If not aligning, it may not be letting sufficient fluid into to be able to compress.
Presuming all the adjustments are correct,and before resorting to the removal of the master cylinder, one thing you might try is what a Healey 100 owner once said to me—-if quick pumping gets pressure, have a suitable piece of timber at hand, and with pressure built up, wedge the pedal down with the timber against the seat frame, and leave it stand overnight. Whilst if sounds odd, he said that he learnt this from other Healey owners, who said that it worked, and it did for him.
Hope this helps in some small way, Cheers
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