the brake (Pass front) is locking. The pads have 1/4"+ of material left. Appears that the calipers will not retract into their hole, but will with a C-clamp. I've never seen calipers have to move so far to hit the rotor. What is the fix, stumped on this one!!!

i think it sounds like the pins that the caliper slide on are stuck.

No dice, the calipers move easily on their pins. The caliper pistons move at least .75" (ABOUT 7 PEDAL PUMPS after the c-clamp retract trick) before the pads contact the rotor. This is a single disc rotor, appx..375" thick. All of the rotors I've ever worked on (40+) had the pads contact within 1/4", less with new pads. Seems the MAX I've seen a piston move is 1" before they leave the comfort of the caliper. Still stumped...

is it posible someone has put the wrong rotors on the car? i cant think off the top of my head what could be causing that. are the pads wearing on both sides of the caliper eavenly?

I will try to find the spec to see if they are for this car. They've been on this car for the last 2 years and only recently have they started to not retract. I'm guessing the hose may be plugged...Thanks for the replies.