GT BrakesStock brakes on the 2.5i are decent and stop well. Personally i never liked the brake feel of the 2.5i. Absolutely no pedal feel for the initial braking and once pressed hard brakes grab all of a sudden with a jerk upsetting the cars posture. After reading about GT/Brembo brake upgrades on our forum, I have decided to buy used calipers from a GT and upgrade. I felt that GT brakes would be good enough for my car. I was very tempted to invest in Brembo's but they were way out of my budget and i would need new wheels/tyres to fit them which is pointless as i have invested in new tyres and used wrx wheels not long ago.

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Purchased set of front and rear brake calipers form facebook marketplace.
Calipers were from a 2006 GT. Previous owner sold me the whole lot with front and rear calipers/ pads and used rotors for $220.
Initially i wanted to just fit everything and use up all the pad material and rotors that i got with them before upgrading. But under closer inspection, front Caliper seals were busted and the previous owner used some kind of sealant to stop leaks or maybe just to stop dust from entering the piston. Sealant was in red colour and was pretty much jammed all over the caliper/pads/shims. After further reading and dismantling of parts i have found that the front pads were of the wrong size. Rear calipers and pads were in good condition with the caliper seals intact considering the age.
I was a bit disappointed but i took this opportunity to lear how to rebuild the calipers. I wanted to do it once and do it right so that i have the intended optimum performance from them. I have also learned about braided brake lines and their advantages so ordered them as well.
Setup includes -GT front and rear calipers.
HEL braided brake lines (6). Two front and 4 rear. Kit comes with banjo bolts and copper crush washers.
316mm front rotors from DBA. Part no DBA T2 - 2650S-10.
290mm rear ventilated rotors from DBA. Part no DBA T2- 653S.
RDA front pads.
TRW rear pads.
Cusco BCS.
New shims
New caliper seal kit for the front and rear (ordered rear ones to change the dust covers and the rubber on caliper slider pins).
Degreased/prepped/primer applied and painted to revive them and make them look good.
3M Silicon paste.
3M Copper anti seize.
Rebuild ProcessesDismantling was a bit tiring as the slider pins were jammed and i don't have a vice to grip the caliper in place while i brake the bolts loose. Some how I managed to crack them open by spraying WD-40 and by using a breaker bar. Once the calpier and brackets were separated i disconnected the brake line and used compressed air (took them to my uni) and a block of wood to push the pistons out without damage. This is dangerous and a block of wood is necessary as the piston will come out with great force. To do this i wrapped the air gun with some tape and tried to push it into the hole where normally brake hose is attached. With a bit of wiggling around i could get it air tight and bam! the piston is out.
This is how the pistons were

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Pistons were pitted and have wear as expected from used old brakes. Piston housing (not sure if it's the right term) was in great condition and no signs of damage or wear were found. I used brake fluid and a piece of scotch brite to gently scrub away the rust and contaminants on the piston. Plenty of brake fluid was used for lubrication. After some scrubbing piston looked new and the surface was smooth. Repeated the same on the other three pistons.
The red stuff you see is the sealant used by the previous owner

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This is how they look after cleaning

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Painted the calipers and brackets while waiting for the reseal kit.

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Now the reassemblyReseal kits were not in stock from Subaru so i used a Febest branded seals. Initially i watched some videos and read online about how to reassemble everything back. It was a bit harder than I thought as i didn't know the technique. I put the inner seals and dust seals in easily but was stuck pushing the piston back inside. Later i tried sliding the dust seal over the piston and then inserting the piston inside. Both ways i failed and ruined 3 reseal kits before I finally got it right with the 4th kit!


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After assembling everything back, I fitted new braided brake lines from HEL with new banjo bolts/copper crush washers and bled the whole system. Still using DOT3 as of now since i had some fresh fluid lying around. I wanted to use the car for sometime and then flush/replace the whole system with DOT 4. Took the car for a drive and did the bedding in processes.
ConclusionBrakes feel amazing from the first drive itself. Pedal feel has improved a lot and it's a lot firmer and much more predictable. I think braided lines made a huge difference for the pedal feel but, after all the parts put together i think it's a collective effort from (bigger rotors/better pads/rebuilt calipers/braided lines/fluid bleeding) IMO that is contributing for pedal feel/stopping power. Driving on the freeway or in city traffic is more peaceful now. Car pulls up without any drama from any speed and without abs kicking in. This is definitely the best upgrade that i have done for my car. The difference is night and day between stock 2.5i and GT brakes. I would recommend this to anyone thinking of upgrading their brakes on 2.5i.

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