The Fiat 500 uses a pin-type caliper system rather than the conventional sliding-pin Allen key design found on most modern cars. Instead of Allen key bolts, the caliper is held by a single horizontal pin running through the bottom, locked in place with a small safety clip.
Once you understand the system it is very accessible. This guide covers full front disc and pad replacement — note that one side has a brake pad wear sensor that must be unplugged and replugged correctly.
When You Need This Job
- Grinding or squealing when braking
- Brake pad wear warning light on the dashboard
- Visible thin pads through the wheel spokes
- Lip on the outer edge of the disc
- Pulling to one side under braking
- Vibration through the brake pedal
Tools You'll Need
Step-by-Step Guide
Remove the wheel and unplug the wear sensor
Remove the front wheel. Unplug the brake pad wear sensor connector and slide the wire out of its retaining clip so it hangs freely.
Pull out the safety clip
Use pliers to pull the small R-clip or safety pin from the bottom of the caliper. This locks the main caliper pin in place.
Knock out the main caliper pin
Using a punch, drive the main horizontal caliper pin out from one side. This releases the caliper from the pad assembly.
Push the piston back
Remove the brake fluid reservoir cap. Use a flat screwdriver against the pad face to push the piston fully back into the caliper.
Remove the pads and inspect
Lift the caliper away and pull the pads out. Check wear — inner pad worn to metal means this job is well overdue.
Wire brush inside the caliper
Carefully clean inside the caliper with a wire brush. Do not damage the rubber seal around the piston.
Remove the caliper carrier
Undo the two 17mm bolts on the caliper carrier and remove it. Hook the caliper to the suspension with a bungee.
Remove the disc
Undo the two 12mm disc retaining bolts and tap the disc off. Clean the hub face with a wire brush.
Fit the new disc
Apply a small amount of copper slip to the hub mating face. Fit the new disc and refit the 12mm retaining bolts.
Refit caliper carrier and new pads
Bolt the carrier back on. Apply copper slip to the pad backing plate ends. Refit the new pads — sensor pad goes on the piston side at the bottom.
Clean the caliper pin and refit
Clean the main pin with sandpaper until smooth. Apply a thin smear of copper slip. Slide it back through the assembly and refit the safety clip.
Reconnect the wear sensor and refit wheel
Route the sensor wire back into its clip and reconnect the connector. Refit the wheel and torque up. Pump the brake pedal before driving.
Torque Specifications
A smooth pin slides freely and ensures even pad contact. Take time to get it properly clean — rough pins cause dragging brakes.
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