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First question, did all this happen when you replaced the master cylinder etc? If so I would be looking at the free travel between the booster & master cylinder. Also look at the free travel between the pedal rod & booster. There must be clearance between all.
Next one, when the pedal goes hard, try cracking the bleeder and see what happens.
It appears to me that you have a booster/master cylinder problem if this only started after replacing parts.
You will also find that the Patrol's and 99.9% of other vehicle's pressure plate do not have springs in them, they have a diaphragm. The springs are found in the clutch plate to take up the shock loads that are applied during operation.
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