I've bought rebuilt rear calipers for my fiero, but can't remove all of the parking brake pieces from my old (I need to return the old ones to get the core, and the new ones don't have any of the parking brake stuff). I got most of the screws out but there is one Torx-40 screw which is rusted away so bad that it instead of a torx star patern on the screw there is now basically just a circle. I've wd40'd it all up and hit it with a hammer a few times to loosen it up, but still can't get any screwdriver or rachet or anything to grip onto it to get it out.

Any ideas on how to remove it?

Sears sells a little craftsman set for that. it has this drillbit/srewdriver deallie that you stick in there and its supposed to get it out.

Just buy new parts from fierostore and leave the frozen parts on when you return for core.
The parts are not to expensive.

I had the exact same problem.
I used a 4" angle grinser to grind the head off the bolt. I found a replacement metric bolt in a junk box from my porsche days.

Is there enough room to get a small pipe wrench like this on it?

I've used different size pipe wrenches to remove stripped or broken bolts and they work well if there is room.

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'84 SE 2.5l
'85 Coupe 2.5l now getting a 3800
'86 SE 2.5l

quote Originally posted by fierohoho: Is there enough room to get a small pipe wrench like this on it?

no, the bracket has a reinforcing lip that effectivly surrounds the screw head. there is no way to get a flat shot at it with the bracket in place.

I had that happen once or twice. (I hate those torx head bolts). I can't remember if it was the front or rear caliper but I used a chisle and hammer. Just hit the head of it enough to make a groove then angle the chisle so that when you hit it with the hammer it will turn the bolt. Then get a pair of vice grips. It was a pain but I eventually got it like this.

I tried the chisel thing, even with a propane torch heating the caliper, and frequent applications of WD40, I got no motion, hence the grinder.

Ok, I had this problem before as well..

What I first tried was to get a pair of vise-grips on it and then spin it off like that. Needless to say, it kept slipping.

So what I did was used my angle grinder and grinded opposite sides of the screw to a flat surface. Then once again I clamped on the vise grips and I was able to keep enough grip on it to get it turned.
You will probably end up grinding into the parking brake piece a little, but it's nothing serious.

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