1G '90 TSI AWD rear caliper rebuild question.

[JzaJet]

I am rebuilding my rear calipers on my 1990 Talon TSI AWD. I have them completely disassembled except for the Guide Pin which is holding the caliper to the bracket. How is the Guide Pin removed? The bolt is recessed into the bracket and there is not enough room to get a socket on it. I checked two different 'shop manuals' (Haynes/Chiltons) and I've checked the manual on CD (and also searched here). None give specific directions for seperating the bracket from the caliper (and thereby removing the Guide Pin) except to say 'pull them apart'.

Once the Lock Pin is removed, does the bracket in fact slide off of the Guide Pin before actually losening the Guide Pin from the caliper (just like how the mounting bracket seperates from the caliper on the 2G front, 2 piston calipers while the Guide Pin is still screwed to the caliper)? I tried simply pulling them apart and it was a no go. I thought I would ask the question here before trying to pound these apart.

If this is not clear, let me know and I will try to clarify. I could potentially get pics if that would help too.

Thanks in advance for any help.

 

[pneumo]

What a coincidence, I was just replacing the brakes on my 92 Talon today! The guide pin just slides out. The rubber boot has some grip, so pinch it and slide it out of it's groove and the pin should slide out of the caliper easily. I hope yours isn't rusted in place. Can you feel the guide pin sliding smoothly? If it's stuck you might try removing the rubber boots and squirting in some Liquid Wrench or something.

 

[JzaJet]

Thanks for the reply.

I'll give that a shot. I was considering just cutting off as much of the rubber boot as I could since I'll be replacing it anyway.

One of the calipers swings very freely on the Guide Pin but the other does not...wonder if the tough one is rusted like you said.

I'll mess with them more tomorrow and report back.

 

[DSM Jeff]

it is probably rusted. i put mine in a vise and sprayed some pb blast and let it get in there, then knocked the caliper back and forth a bit and it came free and i was able to work it out. i bead blasted the rust away and used a good brake grease when reassembling everything.

 

[JzaJet]

Maybe my calipers are different from the ones you guys are talking about, but they just don't slide apart. The Guide Pin is a 10mm bolt that is recessed into the caliper. It is because it's recessed that I cannot get a socket on it. I was able to wedge a flathead screwdriver between the bolt head and the side of the recess and swing the caliper and bracket on the Guide Pin causing the bolt to break loose. Doing this, I was able to eventually unscrew the Guide Pin and remove it. Upon looking at it, there is a lip that the bolt head sits on which would make it impossible to just pull it apart as suggested.

It almost looks like I would need a very thin-walled 10mm socket to remove or install the Guide Pins.

Like I said, I was able to get one caliper apart using the above method, but the other one won't break free. Also, I have no idea how I will re-install the Guide Pin when I am putting them back together.

Anyone know of a special tool, such as a very thin-walled socket, that has to be used on the Guide Pins?

Maybe I will try to post some picks later to make this clearer.

 

[JzaJet]

Here's a pic showing the recessed Guide Pin.

Any ideas how to remove/install this?

 

[Sean485]

Place left foot on caliper bracket, grab caliper with 2 hands, pull up and twist back and forth

The caliper is supposed to slide on that pin, the bolt holds the pin to the caliper bracket, not the caliper itself to the bracket.