Pontiac Fiero 1984-1988 Repair Guide

Brake Caliper

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REMOVAL & INSTALLATION



1984-87 Models
  1. Remove 2 / 3 of the brake fluid from the master cylinder.
  2.  
  3. Raise the vehicle and support it safely with jackstands.
  4.  
  5. Remove the wheel and tire assembly.
  6.  
  7. Install two lug nuts to retain the rotor.
  8.  
  9. Remove the bolt attaching the fluid inlet fitting to the caliper. Plug the brake hose after removal.
  10.  
  11. Remove the boots and mounting bolts using a No. 50 Torx® wrench.
  12.  
  13. Position a 4-inch adjustable pliers over the inboard surface of the caliper housing and caliper support bracket.
  14.  
  15. Squeeze the pliers to compress the piston back into the caliper bore and provide clearance between the linings and rotor.
  16.  
  17. Inspect the mounting bolts and sleeves for corrosion. If corrosion is found, use new bushings, bolts and sleeves when installing the caliper.
  18.  
  19. Liberally fill both cavities in the caliper housing between the bushings with silicone grease.
  20.  

To install:

  1. Position the sleeves and boots in the caliper.
  2.  
  3. Position the caliper over the rotor in the mounting bracket.
  4.  
  5. Install the mounting bolts and torque to 21-35 ft. lbs. (28-48 Nm).
  6.  
  7. Measure the clearance between the caliper and bracket stops and if necessary file the ends of the bracket stops to provide the proper clearance.
  8.  
  9. Install the fluid inlet fitting and torque to 18-30 ft. lbs. (25-40 Nm).
  10.  
  11. Install the wheel and tire assembly. Torque the lug nut to 100 ft. lbs. (136 Nm).
  12.  
  13. Fill the master cylinder to the proper level and bleed the brake system as outlined in the Brake System Bleeding procedures in this section.
  14.  

1988 Models


Click image to see an enlarged view

Fig. Fig. 1 View of the caliper mounting components (top); exploded view of the caliper sleeves and sleeve boots (bottom)-1988 models

  1. Remove 2 / 3 of the brake fluid from the master cylinder.
  2.  
  3. Raise the vehicle and support it safely with jackstands.
  4.  
  5. Remove the wheel and tire assembly.
  6.  
  7. Install two lug nuts to retain the rotor.
  8.  
  9. Remove the bolt attaching the fluid inlet fitting to the caliper. Plug the brake hose after removal.
  10.  
  11. Remove the brake pads as outlined in the Brake Pad removal procedures in this section.
  12.  
  13. Remove the caliper-to-mounting bracket Torx® #55 bolts. Do not confuse the mounting bolts with the bridge bolts, which have a standard hex head.
  14.  
  15. Remove the caliper housing from the mounting bracket.
  16.  
  17. Remove the sleeve and sleeve boots.
  18.  

To install:

Make sure the sleeves are installed with the large holes facing inboard. If the sleeves are installed backwards, damage to the mounting bracket may result.

  1. Install the sleeve and sleeve boots in the caliper housing as follows:
  2.  
    1. Lubricate the sleeve and mounting hole in the caliper housing with silicone grease.
    2.  
    3. Lubricate both inside and outside sealing beads on the sleeve boots with silicone grease.
    4.  
    5. Push the sleeve into the mounting bolt hole past the inside of installed sleeve boot position.
    6.  
    7. Install the remaining sleeve boot.
    8.  
    9. Push the sleeve back the other way and seat the beads of both sleeve boots.
    10.  

  3. Install the caliper housing over the rotor to the mounting bracket with the mounting Torx® #55 bolts. Torque the bolts to 74 ft. lbs. (100 Nm). Make sure the mounting bolts are properly torqued.
  4.  
  5. Install the brake hose with new copper washer and torque the hose bolt to 33 ft. lbs. (45 Nm).
  6.  
  7. Install the brake pads as outlined in the Brake Pad installation procedures in this section.
  8.  
  9. Fill the master cylinder to the proper level and bleed the brake system as outlined in the Brake System Bleeding procedures in this section.
  10.  
  11. Install the wheel and tire assembly. Torque the lug nut to 100 ft. lbs. (136 Nm). Lower the vehicle and pump the brake pedal before moving the vehicle.
  12.  

OVERHAUL



1984-87 Models


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Fig. Fig. 2 Exploded view of the front caliper assembly-1984-87 models



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Fig. Fig. 3 Use compressed air to carefully remove the caliper piston



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Fig. Fig. 4 Use a prytool to remove the caliper piston boot



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Fig. Fig. 5 Use a seal driver to install the new caliper boot

  1. Remove the caliper and pads as outlined in this section.
  2.  
  3. Place some cloths in front of the piston. Remove the piston by applying compressed air to the fluid inlet fitting. Use just enough air pressure to ease the piston from the bore.
  4.  


CAUTION
Do not try to catch the piston with your fingers, as it could result in serious injury.

  1. Remove the piston boot using a suitable prying tool, working carefully so that the piston bore is not scratched.
  2.  
  3. Remove the bleeder screw. If the bleeder screw can not be removed or it breaks, the caliper assembly will have to be replaced.
  4.  
  5. Inspect the piston for scoring, nicks, corrosion, wear, etc., and replace the piston if any defects are found.
  6.  
  7. Remove the piston seal from the caliper bore groove using a piece of wood or plastic. Do not use a metal tool as damage to the bore could result. Very light wear can be cleaned up with a crocus cloth. Use finger pressure to rub the crocus cloth around the circumference of the bore (do not slide it in and out). More extensive wear or corrosion warrants replacement of the part.
  8.  
  9. Clean any parts which are to be reused, in denatured alcohol. Dry them with compressed air or allow them to air dry. Do not wipe the parts dry with a cloth, which will leave behind bits of lint.
  10.  
  11. Lubricate the new seal, provided in the repair kit, with clean brake fluid. Install the seal in its groove, making sure it is fully seated and not twisted.
  12.  
  13. Install the new dust boot on the piston. Lubricate the bore of the caliper with clean brake fluid and insert the piston into its bore. Position the boot in the caliper housing and seat with a seal driver, GM tool no. J-2907.
  14.  
  15. Install the bleeder screw, tightening to 116 inch lbs. (13 Nm). Do not overtighten.
  16.  
  17. Install the pads, install the caliper and bleed the brake system.
  18.  

1988 Models


Click image to see an enlarged view

Fig. Fig. 6 Exploded view of the front caliper assembly-1988 models



Click image to see an enlarged view

Fig. Fig. 7 Installation of the caliper sleeve and sleeve boot assembly-1988 models

  1. Remove the caliper and pad assembly as previously outlined.
  2.  
  3. Inspect the bridge for cracks.
  4.  
  5. Remove the bleeder valve. If the bleeder can not be removed or it breaks, replace the caliper.
  6.  
  7. Remove the two bridge bolts only if the bridge is damaged and has to be replaced.
  8.  

The caliper can be overhauled without removing the bridge.

  1. Use shop towels as a pad over the bridge during piston removal. Remove the piston by applying compressed air into the caliper inlet hole.
  2.  


CAUTION
Do not try to catch the piston with your fingers, as it could result in serious injury!

  1. Inspect the piston and bore for scoring, nicks and corrosion to the piston chrome plating. Replace the piston or bore if any of these conditions exist.
  2.  
  3. Remove the piston boot by prying up with a screwdriver.
  4.  
  5. Remove the piston seal using a plastic seal removing tool. Do not use any metal tool to remove the piston seal.
  6.  
  7. Use crocus cloth to polish out light corrosion. Replace parts if they will not clean up with crocus cloth.
  8.  

Assembly:
  1. Clean all parts in denatured alcohol and dry with compressed air.
  2.  
  3. Install the bridge and bolts, if removed. Torque the bolts to 74 ft. lbs. (100 Nm).
  4.  
  5. Install the bleeder valve and torque to 116 ft. lbs. (13 Nm).
  6.  
  7. Lubricate the new piston seal with new brake fluid and install the seal into the piston bore. Make sure the seal is not twisted.
  8.  
  9. Install the piston with the boot into the bore and push down in a rocking motion. Seat the piston boot onto the caliper housing using your fingers or a small piece of wood.
  10.  
  11. Install the caliper as previously described in this section.
  12.  

 
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