Pontiac Fiero 1984-1988 Repair Guide

Brake Caliper

Print

REMOVAL & INSTALLATION





Click image to see an enlarged view

Fig. Fig. 1 Loosen the brake hose mounting bolt, then ...



Click image to see an enlarged view

Fig. Fig. 2 ... disengage the hose from the caliper and remove the copper washers

1984-87 Models
  1. Remove 2 / 3 of the brake fluid from the master cylinder assembly.
  2.  
  3. Raise the vehicle and support it safely with jackstands.
  4.  
  5. Remove the wheel and tire assembly then install two lug nuts to retain the rotor.
  6.  
  7. Remove the bolt holding the brake hose to the caliper. Plug the hose to prevent contamination from entering the hose. Also remove the two copper washers.
  8.  
  9. Loosen the tension on the parking brake cable at the equalizer.
  10.  
    1. Remove the cable and spring from the lever.
    2.  
    3. Remove the locknut while holding the lever.
    4.  
    5. Remove the lever, lever seal and anti-friction washer.
    6.  

  11. Remove the caliper mounting bolts with a No. 50 Torx® wrench.
  12.  
  13. Position 4-inch adjustable pliers over the inboard surface of the caliper housing and outboard surface of the mounting bracket.
  14.  
  15. Squeeze the pliers to compress the piston back into the caliper bore and provide clearance between the brake pad and the rotor.
  16.  
  17. Remove the caliper from the rotor and mounting bracket.
  18.  

To install:

  1. Bottom the piston into the caliper bore using tool J-36621. Turn the left piston in a counterclockwise direction and the right piston in a clockwise direction to move the piston back into the bore. The piston must be bottomed in the bore to install new brake pads.
  2.  
  3. Inspect the lever seal and anti-friction washer for wear, mounting bolts and sleeves for corrosion and replace the component is these conditions exist.
  4.  
  5. Liberally fill both the cavities in the housing between bushings and sleeves with silicone grease.
  6.  
  7. Install the sleeves into the caliper, if removed.
  8.  
  9. Install the brake pads as outlined earlier in this section.
  10.  
  11. Install the caliper over the rotor and engage into the mounting bracket. Torque the mounting Torx® bolts to 30-45 ft. lbs. (41-61 Nm).
  12.  
  13. Install the brake hose with new copper washer. Torque the bolt to 30 ft. lbs. (40 Nm).
  14.  
  15. Lubricate the lever seal with silicone grease and install the lever, anti-friction washer and hex nut. Make sure the lever stays properly installed on the actuator screw hex as the nut is torqued. Torque the nut to 30-40 ft. lbs. (41-54 Nm). Rotate the lever back against the stop on the caliper.
  16.  
  17. Install the spring and parking brake cable, if removed.
  18.  
  19. Install the wheel assemblies and torque the lug nuts to 100 ft. lbs. (136 Nm). Bleed the brake system as outlined in the Brake System Bleeding portion of this section.
  20.  
  21. Lower the vehicle and pump the brake pedal before moving the vehicle.
  22.  
  23. Fill the fluid reservoir to the proper level.
  24.  

1988 Models
  1. Remove 2 / 3 of the brake fluid from the master cylinder assembly.
  2.  
  3. Raise the vehicle and support it safely with jackstands.
  4.  
  5. Remove the wheel and tire assembly then install two lug nuts to retain the rotor.
  6.  
  7. Remove the bolt holding the brake hose to the caliper. Plug the hose to prevent contamination from entering the hose. Also remove the two copper washers.
  8.  
  9. Remove the parking brake cable and return spring from the parking brake lever. The cable adjuster may have to be loosened.
  10.  
  11. Remove the two caliper mounting Torx® #55 bolts. Do not confuse these with the hex bridge bolts.
  12.  
  13. Remove the caliper from the mounting bracket and rotor.
  14.  
  15. Remove the sleeves and sleeve boots.
  16.  

To install:

  1. Inspect the mounting bolts for corrosion and the sleeve boots for cuts or deterioration. Replace the component if these conditions exist.
  2.  

Make sure the sleeves are installed with the large holes facing inboard. Damage to the bolt threads may result if installed incorrectly.

  1. Install the sleeves and boots into the caliper housing. Lubricate all parts with silicone grease before installation.
  2.  
  3. Install the brake caliper over the rotor into the mounting bracket and torque the two Torx® bolts to 74 ft. lbs. (100 Nm). Make sure the mounting Torx® bolts are properly torqued.
  4.  
  5. Install the brake hose, two copper washers and retaining bolt to the caliper. Torque the hose retaining 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. Install the spring and parking brake cable, if removed.
  10.  
  11. Bleed the brake system as outlined in the Brake System Bleeding procedure in this section.
  12.  
  13. Install the wheel assemblies and torque the lug nuts to 100 ft. lbs. (136 Nm).
  14.  
  15. Lower the vehicle and pump the brake pedal before moving the vehicle.
  16.  
  17. Fill the fluid reservoir to the proper level.
  18.  

OVERHAUL



1984-87 Models


Click image to see an enlarged view

Fig. Fig. 3 Exploded view of the rear brake caliper assembly-1984-87 models



Click image to see an enlarged view

Fig. Fig. 4 Use tool J-23072 or its equivalent to install the piston in the caliper bore-1984-87 models



Click image to see an enlarged view

Fig. Fig. 5 Bleed the brake system after installation of the caliper

  1. Remove the brake pads and caliper as outlined in the Brake Pad and Caliper portions of this section.
  2.  
  3. Remove the bleeder valve and cap. If the bleeder will not come out or breaks off in the housing, the caliper will have to be replaced.
  4.  
  5. Remove the brake pad dampening spring from the end of the piston. Refer to the Rear Brake Caliper exploded view.
  6.  
  7. Remove the parking brake lever, nut and washers from the housing.
  8.  
  9. Support the caliper in a vise. Using a wrench, rotate the actuator screw in the parking brake direction (right side rotates clockwise and left side rotates counterclockwise).
  10.  
  11. Remove the actuator screw by pressing on the threaded end. Remove the shaft seal and thrust washer.
  12.  
  13. Remove the piston boot by prying it off with a small prybar. Do not damage the housing.
  14.  
  15. Remove the piston by applying compressed air to the caliper fluid inlet.
  16.  


CAUTION
Do not try to catch the piston with your fingers, as it could result in serious injury. Use a piece of wood or rolled up towels to prevent injury.

  1. Remove the piston seal with a piece of wood or plastic so not to damage the piston bore with a metal tool.
  2.  

To assemble:
  1. Inspect the caliper bore and seal groove for scoring or nicks. Inspect the piston for scores or deterioration in the chrome finish. If these conditions can not be polished out with soft crocus cloth, replace as necessary.
  2.  
  3. Clean all parts in denatured alcohol and dry with compressed air.
  4.  
  5. Install the bleeder valve and torque to 80-140 inch lbs. (9-16 Nm).
  6.  
  7. Install the parking brake bracket, if removed, and torque the attaching bolt to 24-39 ft. lbs. (33-52 Nm).
  8.  
  9. Lubricate the new seals and caliper housing with new brake fluid. Install the piston seal making sure it is not twisted. Install the piston boot onto the piston with the inside lip of the boot in the piston groove and fold the boot toward the end of the piston that contacts the inboard brake pad.
  10.  
  11. Install the thrust washer onto the actuator screw with the round edge surface toward the housing.
  12.  
  13. Install the balance spring into the piston recess.
  14.  
  15. Lubricate the piston and seal with new brake fluid. Start the piston into the piston bore and push the piston to the bottom of the bore using a piston installing tool J-23072. Refer to the illustration.
  16.  
  17. Lubricate the anti-friction washer, lever seal and over end of actuator screw.
  18.  
    1. Make sure the sealing bed on the lever seal is against the housing.
    2.  
    3. Install the lever on the actuator screw.
    4.  
    5. Rotate the lever away from stop slightly and hold while installing the nut.
    6.  
    7. Torque the nut to 30-40 ft. lbs. (41-54 Nm).
    8.  

  19. Install the boot in the caliper counterbore and seat using tool No. J-28678 or equivalent.
  20.  
  21. Install the dampening spring in the groove in the end of the piston. It may be necessary to move the parking brake lever off the stop to extend the piston and make the spring groove accessible.
  22.  
  23. Install the caliper and brake pads as outlined earlier in this section.
  24.  
  25. Bleed the brake system as outlined in the Brake System Bleeding procedure in this section.
  26.  
  27. Install the wheel assemblies and torque the lug nuts to 100 ft. lbs. (136 Nm).
  28.  
  29. Lower the vehicle and pump the brake pedal before moving the vehicle.
  30.  
  31. Fill the fluid reservoir to the proper level.
  32.  

1988 Models


Click image to see an enlarged view

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

  1. Remove the caliper assembly from the vehicle as outlined earlier in this section.
  2.  
  3. Remove the bleeder valve from the housing. If the bleeder with not come out or breaks in the housing, the caliper will have to be replaced.
  4.  
  5. Remove the parking brake nut, lever and seal.
  6.  
  7. Check the caliper bracket and bridge for cracks. Remove the two bridge bolts only if bridge or bracket is cracked or damaged. The caliper can be overhauled without removing the bridge assembly.
  8.  
  9. Remove the piston assembly as follows:
  10.  
    1. Use shop towels or a piece of wood as a pad over the bridge and under the caliper housing during piston removal.
    2.  
    3. Use a wrench to turn the actuator screw in the parking brake apply direction to work the piston assembly out of the caliper housing.
    4.  

  11. Inspect the piston and bore for nicks, scoring and corrosion. If the condition can not be removed with soft crocus cloth, replace the defective part.
  12.  
  13. Remove the actuator screw by pressing on the thread end.
  14.  
  15. Remove the balance spring, shaft seal and thrust washer from the actuator screw.
  16.  
  17. Remove the piston boot being careful not to scratch the piston bore.
  18.  
  19. Remove the piston seal with a plastic or wooden seal removal tool. Do not use any metal tools.
  20.  
  21. Clean the piston bore and seal groove with crocus cloth.
  22.  

To assemble:
  1. Clean all parts with denatured alcohol and dry with compressed air.
  2.  
  3. If the bridge was removed, torque the bolts to 74 ft. lbs. (100 Nm).
  4.  
  5. Install the bleeder valve and torque to 116 inch lbs. (13 Nm).
  6.  
  7. Lubricate the new piston seal with new brake fluid and install into the seal groove. Make sure the seal is not twisted.
  8.  
  9. Install the thrust washer onto the actuator screw with the copper side of washer towards the piston.
  10.  
  11. Lubricate the shaft seal and piston boot. Install the boot onto the piston.
  12.  
  13. Lubricate the actuator screw and install with the shaft seal and thrust washer into the caliper housing.
  14.  
  15. Install the balance spring into the housing bore with the end of the spring in the recess at the bottom of the bore.
  16.  
  17. Lubricate the piston and boot. Install the assembly by pushing the piston toward the bottom of the bore using a piston installer tool J-36623 or equivalent. Turn the actuator screw as necessary to move the piston to the bottom of the bore.
  18.  
  19. Lubricate the parking lever seal and install so that the rubber sealing bead on the seal is against the lever and the copper side is against the housing.
  20.  
  21. Hold the lever back against the stop on the housing while torquing the nut. Install the lever and nut and torque to 35 ft. lbs. (47 Nm).
  22.  
  23. Set the piston boot to the housing by pressing down with a boot tool J-36622 and J-36623 or equivalent. A piece of wood can be used.
  24.  
  25. Install the caliper and brake pads as outlined earlier in this section.
  26.  
  27. Bleed the brake system as outlined in the Brake System Bleeding procedure in this section.
  28.  
  29. Install the wheel assemblies and torque the lug nuts to 100 ft. lbs. (136 Nm).
  30.  
  31. Lower the vehicle and pump the brake pedal before moving the vehicle.
  32.  
  33. Fill the fluid reservoir to the proper level.
  34.  

 
label.common.footer.alt.autozoneLogo