Well I went to bleed my brake system and one of the bleeder screws broke off. I used PB blast on them and reapplied it two to three times a day for three days and it still broke off. What is the best way to remove the broken screw. Can I just drill the old screw out and retap? And if so where would I get the tap from? Thanks for the help.

At the very least, you need a bleeder repair kit. This has a new screw and seat. MotorMite and others make them. (check the motormite paper catalog at your local parts stores.) You drill and tap a hole and screw the kit into the new opening.

You are better off just replacing the caliper in most cases. If the bleeder is in bad shape the rest probably isn't that great either.

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RIP Crew of Columbia. 01-Feb-03

Well I removed the broken bleeder screw and installed a new one. But I can't get it to seal. So I am replacing the caliper. My question now is what size are the Torx bolts holding the caliper on. My repair manual says they are a T50 but that will not fit and a T45 seems to loose. I remember reading some where in the forum that it was a T47 I think. And what is the size of the Torx bolt hold the parking brake braket on. Thanks again for the help.

T40.

Some of this will be redundant, but I just R&Red a rear caliper this afternoon, so sizes are pretty fresh in my memory:

Caliper to knuckle: T50, 30ft-lbf.

Ebrake bracket to caliper: T40, or some rebuilt calipers used 14mm hex bolt. (FWIW, reinstalled with antiseize, as this particular one was a bear to remove).

Ebrake actuator lever attach: 18mm.

Ogre taught me this...
To install Ebrake actuator lever:
Install seal, antifriction washer, then lever, then self-locking 18mm nut...

All manuals I have (including Helms factory manual) show seal and antifriction washer swapped... don't do it that way! Use lots of caliper grease on this area. Key thing is: the lever must move freely, w/o binding.

Hex on Ebrake shaft: 14mm.

Flexible brake line to strut: 13mm.

Suggest you read brake articles in Ogre's Cave thoroughly. They are a great help to me. Obviously, if there's one thing that needs to be done right, it's brakes. Good luck, !

[This message has been edited by StuGood (edited 03-23-2003).]

Thanks for the info. But I just read in the http://home.t-online.de/home/O_Scholz/fieroidx.html websit that the caliper bolt is actucally a special T47 not a T50. But I will try the T50 again.

You are right StuGood on all accounts. I just finished the caliper install and the caliper bolt where a T50. The rest of your bolt sizes where also correct. Thanks again.