SOLVED.......
Well it turns on the lower caliper slide pin was rusted tight, there was a crack in the plastic cover. We ended up loading it with Liquid Wrench, letting it soak it for a bit. Once that didn't work, we took a small torch and heated up the bolt. The bolt eventually came free!
It is now replaced as well as the cover and we are back in business. So much for a 2 hour job, turned into 3 days.
Thanks for everyones help.