Pontiac Fiero 1984-1988 Repair Guide

Brake Pads

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INSPECTION




CAUTION
Some brake pads contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.

The pad thickness should be inspected every time that the wheels are removed. Pad thickness can be checked by looking down through the inspection hole in the top of the caliper. If the thickness of the pad is worn to within 0.030 in. (0.76mm) of the rivet at either end of the pad, all the pads should be replaced. A thermal material is sandwiched between the lining and backing. Don't include this material when determining the lining thickness. This is the factory recommended measurement. Your state's automobile inspection laws may be different.

Always replace all pads on both front wheels at the same time. Failure to do so will result in uneven braking action and premature wear.

REMOVAL & INSTALLATION



1984-87 Models


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Fig. Fig. 1 Typical rear disc brake assembly used on the Fiero



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Fig. Fig. 2 After relieving the tension at the equalizer, use a pair of pliers to disengage the cable from the lever ...



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Fig. Fig. 3 ... then remove the return spring assembly



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Fig. Fig. 4 Remove the lever retaining locknut ...



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Fig. Fig. 5 ... then remove the lever from the caliper assembly



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Fig. Fig. 6 Remove the parking brake lever seal, then ...



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Fig. Fig. 7 ... remove the anti-friction washer



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Fig. Fig. 8 Loosen the caliper mounting bolts



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Fig. Fig. 9 Remove the bolts from the caliper, then ...



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Fig. Fig. 10 ... use a pair of pliers to compress the caliper piston



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Fig. Fig. 11 Remove the caliper assembly from the rotor



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Fig. Fig. 12 Support the caliper with a bungee cord or a piece of wire. Never let the caliper hang by the brake hose



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Fig. Fig. 13 Remove the outboard brake pad from the caliper ...



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Fig. Fig. 14 ... then remove the inboard pad



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Fig. Fig. 15 The notched piston must be turned into its bore with a special tool before installing new pads



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Fig. Fig. 16 Exploded view of the parking brake lever assembly-1984-87 models



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Fig. Fig. 17 Rear caliper mounting retainers and their locations-1984-87 models



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Fig. Fig. 18 When installing the inboard brake pad and retainer, make sure the D-shaped tabs on the shoe engage the D-shaped notches in the caliper piston



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Fig. Fig. 19 Make the ends of the spring on the outboard pad snap into position in the caliper recess during pad installation


CAUTION
Some brake pads contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.

  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. Loosen the tension on the parking brake cable at the equalizer.
  8.  
    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.  

  9. Remove the caliper mounting bolts with a No. 50 Torx® wrench.
  10.  
  11. Position 4-inch adjustable pliers over the inboard surface of the caliper housing and outboard surface of the mounting bracket.
  12.  
  13. Squeeze the pliers to compress the piston back into the caliper bore and provide clearance between the brake pad and the rotor.
  14.  

Use the pliers only to move the caliper back far enough to remove the caliper and brake pad assemblies. The caliper has to be turned into the bottom of the bore using a Caliper Piston Turning Tool.

  1. Remove the caliper from the rotor and mounting bracket and support it to prevent strain on the brake hose.
  2.  
  3. Use a suitable tool and disengage the shoe buttons from the holes in the caliper and remove the brake pad assemblies.
  4.  
  5. Remove the sleeves from the mounting bolt holes.
  6.  
  7. Remove the boots and bushings from the caliper.
  8.  

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. Use new bushings, boots and sleeves in the mounting bolt holes and lubricate these parts with a silicone grease.
  4.  
  5. Use a new two-way check valve and press into the end of the piston.
  6.  
  7. Install the inboard shoe and lining into the caliper and make sure that the D-shaped tabs on the shoe will engage with the D-shape notches in the piston. Also make sure the wear sensor is at the leading edge of the shoe during forward wheel rotation. Slide the edge of the inboard metal shoe under the edge of the dampening spring and snap the shoe into position against the piston.
  8.  

If the D-shaped tabs and notches do not line up, the piston will have to be turned. Pontiac recommends the use of Tool No. J-7624 or its equivalent to turn the piston.

  1. Install the outboard shoe and lining and make sure the ends of the spring on the outboard shoe snap into the caliper recesses.
  2.  
  3. Position the caliper over the rotor mounting bracket and tighten the mounting bolts to 30-45 ft. lbs. (41-61 Nm).
  4.  
  5. Install the parking brake cable lever antifriction washer and lever seal and lubricate the lever seal with silicone brake lube.
  6.  
  7. Install the lever on the actuator screw with the lever pointing in the direction shown in the illustration.
  8.  
  9. Make sure the lever stays properly installed on the actuator screw then torque the nut to 30-40 ft. lbs. (41-54 Nm).
  10.  
  11. Rotate the lever back against the stop on the caliper and install the spring.
  12.  
  13. Install the parking brake cable. Tighten the cable at the equalizer until the lever starts to move off the stop on the caliper. Loosen the adjustment until the lever moves back against the stop.
  14.  
  15. Install the wheel and tire assembly and torque the lug nuts to 100 ft. lbs. (136 Nm).
  16.  
  17. Fill the master cylinder and check the operation of the brake pedal.
  18.  
  19. Lower the vehicle and pump the brake pedal a few times before the vehicle is moved.
  20.  

1988 Models


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Fig. Fig. 20 Exploded view of the rear brake pad and caliper housing assembly-1988 models



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Fig. Fig. 21 Use tool J-36621 or its equivalent to compress the caliper piston



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Fig. Fig. 22 Remove the spring pins from the caliper housing using the proper tools-1988 models



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Fig. Fig. 23 Location of the rear caliper mounting components-1988 models


CAUTION
Some brake pads contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.

  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.  


CAUTION
Be sure to catch the springs when removing spring pins. Springs may fly out causing personal injury.

  1. Remove the spring pins by connecting a spring pin removing tool J-36620 onto J-6125-1B or equivalent. Thrust weight on J-6125-1B outward against the tool handle to drive the pin out.
  2.  
  3. Remove the springs from the inboard and outboard pad flanges.
  4.  
  5. Remove the two brake pads by twisting and pulling straight out of the caliper housing. A locking pliers may have to be used to remove the pads.
  6.  
  7. Remove the two way check valve from the end of the piston assembly using a small screwdriver.
  8.  

If leakage is noted from the piston hole after the check valve is removed, the caliper will have to be overhauled or replaced.

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. Lubricate a new two way check valve with silicone grease and install into the end of the piston assembly.
  4.  
  5. Install the inboard brake pad with the wear sensor at the leading edge of the pad during forward wheel rotation. Install the outboard brake shoe.
  6.  
  7. Install one spring pin while aligning the holes in the pads. Tap in the pin with a soft brass drift and hammer until the end of the pin just emerges from the inboard face of the caliper housing.
  8.  

Do not use a steel drift to drive in the spring pins. This will damage the pin ends and make later removal of pins difficult.

  1. Install the two springs and remaining spring pin. Position the pins so that the slots in the pins face each other. Make sure the springs are centered on the pad flanges with each spring end projecting and equal distance under the pins.
  2.  
  3. Install the parking brake cable. Tighten the cable at the equalizer until the lever starts to move off the stop on the caliper. Loosen the adjustment until the lever moves back against the stop.
  4.  
  5. Install the wheel and tire assembly and torque the lug nuts to 100 ft. lbs. (136 Nm).
  6.  
  7. Fill the master cylinder and check the operation of the brake pedal.
  8.  
  9. Lower the vehicle and pump the brake pedal a few times before the vehicle is moved.
  10.  

 
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