Rear Brake caliper ...

[goldiefish]

Trying to replace my Brake pads at the moment. Simple enough Job I thought. Two bolts to remove to get the old pads off(not including the plug screw.
New pads in hand I set to work. Took off the Caliper(1 bolt) then went to work on the pin that holds the pads in position.
Just the small matter of getting off the plug screw. Flat head slips off it.
Bigger flat head slips off it.
Successive flat head screw drivers slowly chew away at the slot in this plug screw.
Going against all good advice, drown the caliper with wd40, leave overnight.
Two days later, still no budge on the plug screw. Have taken to using the edge of the screwdriver as a punch, to try and get some movement with the plug screw but still nothing.
What was once a single slot, now resembles a vague X as the corners of the slot wear away with ever attempt to move it. Even the Impact driver made no "impact" apart from further grinding away the slot.

My experst have told me that the real difficulty should be getting out the bolt underneath, but with a good set of allen keys I don't forsee any real difficulty.

But how do I get that bloody plug screw off, and why did the last owner think it was a good idea to weld it in?(I'm only assuming)

Thanks.

[lootch67]

My initial thought was to suggest the impact driver but since you've already been down that road it looks like I've nothing to say... Mmm, it's a foolish man who, with nothing to say, give wordy evidence of the fact. I'll go to bed now shall I.....

[Lord Stig]

I would think the only solution would be a stud extractor. Drilling the cap should be fairly easy - as you have found out, it's soft! That approach will work, have no fear.

I have some spare (used) caps if you want a replacement (having replaced all my calipers recently). PM me with your address and I'll pop one in the post...

Stig

[Maverick]

Replaced my rear pads last week and had to resort to the impact driver, a few solid hits and it came loose, those caps are made form chocolate though

[treehugger]

Hmm. Remember trying to do back pads last year and everything was sooooo tight - I bought another caliper.
Once I had the chocolate plug out, the pins were solid. Nothing short of semtex would shift them. Needed bike to run, so bit expensive bullet

[barftone]

Bit of coppaslip on the new one or replace the pins with stainless ones with the proud heads on them (motocross dealers normally sell them). You can get a t bar socket on to extract them easily.