My front calipers make this crunching, popping, groaning noise when I apply heavy pedal pressure.
It goes away when I grease the ears of the pads, but seems to come back after a track day.
Does anyone know what might be causing this, and how I can solve it permantly?

 

It seems like it might actually be the caliper itself, not the pins and pads. Maybe the metal has heat fatigued?

 

Is the temperature rating of your grease high enough? Since they're floating pads they should move freely on the pins. You can try greasing the backs or the shims if you're using them.

 

Probably not. It's just generic brake grease. I guess I need something that will handle much higher temperatures.

Putting on some slightly thicker pads (old take-offs) significantly cut down on the noise, so I think putting new pads on will make the sound go away again (it did before). I think maybe the pistons are sticking a bit when they're extended.

Another possibility is that tapered wear might be causing the noise. It's only about a 1 mm taper, though.

 

Do you have the brake pad guides installed? The little sheetmetal clips that the brake tabs ride in?

 

https://www.summitracing.com/parts/p...LAj3D30m531ghw

Make sure all of your caliper and pad springs are in place as well.

 

The front brakes don't have brake pad guides.

 

I noticed that the brakes make the noise regardless or whether any of the hardware is in place.
I've got some high-temp grease and fresh pads coming.

 

New pads fixed it. Not sure what the cause was.

I’m a little disappointed I couldn’t get a bit more life out of my old pads, but having new pads helps prevent brake fade.