Hyundai Sonata: Brake System / Rear Disc Brake Repair procedures

Removal
[General Type]
1.
Raise the vehicle, and make sure it is securely supported.
2.
Remove the wheel cap(A).

   
Be careful not to damage to the wheel cap(A) when removing the it.
3.
Remove the front wheel and tire (A) from front hub.

Tightening torque:
88.2 ~ 107.8 N.m (9.0 ~11.0 kgf.m, 65.0 ~ 79.5 lb-ft)

   
Be careful not to damage to the hub bolts when removing the front wheel and tire (A).
4.
Loosen the guide rod bolt (B) and pivot the caliper (A) up out of the way.

Tightening torque :
21.6 ~31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)

5.
Replace pad shim (D), pad retainers (C) and brake pads (B) in the caliper bracket (A).

6.
Loosen the hose eyebolt (B) and caliper mounting bolts (C), then remove the rear caliper assembly (A).

Tightening torque :
Caliper assembly to carrier (C) :
78.5 ~ 98.1 N.m (8.0 ~ 10.0 kgf.m, 57.9 ~ 72.3 lb-ft)
Brake hose to caliper (B) :
24.5 ~ 29.4 N.m (2.5 ~ 3.0 kgf.m, 18.1 ~ 21.7 lb-ft)

   
Do not loosen the hose eyebolt (B) when replacing the rear disc. Fix the rear brake caliper with wire to the other components after loosening the brake caliper mounting bolts (C).
7.
Remove the rear brake disc by loosening the screws (A).

[EPB Type]
1.
Raise the vehicle, and make sure it is securely supported.
2.
Remove the wheel cap (A).

   
Be careful not to damage to the wheel cap(A) when removing the it.
3.
Remove the front wheel and tire (A) from front hub.

Tightening torque:
88.2 ~ 107.8 N.m (9.0 ~ 11.0 kgf.m, 65.0 ~ 79.5 lb-ft)

   
Be careful not to damage to the hub bolts when removing the front wheel and tire (A).
4.
Release the EPB, push the EPB switch or using GDS.
(Refer to Paking brake - "Electric Parking Brake")
5.
Loosen the guide rod bolt (B) and pivot the caliper (A) up out of the way.

Tightening torque :
21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)

6.
Replace pad shim (D), pad retainers (C) and brake pads (B) in the caliper carrier (A).

7.
Disconnect the EPB connector(A).

8.
Loosen the brake hose eyebolt (B).

Tightening torque :
24.5 ~ 29.4 N.m (2.5 ~ 3.0 kgf.m, 18.1 ~ 21.7 lb-ft)

9.
Loosen the mounting bolt (A) and then remove the rear brake caliper assembly.

Tightening torque :
78.5 ~98.1 N.m (8.0 ~10.0 kgf.m, 57.9 ~72.3 lb-ft)

10.
Remove the rear brake disc by loosening the screws (A).

Replacement
Rear brake pads
1.
Loosen the guide rod bolt (B) and pivot the caliper (A) up out of the way.

Tightening torque:
21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)

2.
Replace pad shim (D), pad retainers (C) and brake pads (B) in the caliper carrier (A).

Inspection
Rear Brake Disc Thickness Check
1.
Check the brake pads for wear and fade.
2.
Check the brake disc for damage and cracks.
3.
Remove all rust and contamination from the surface, and measure the disc thickness at 8 points, at least, of same distance (5mm) from the brake disc outer circle.

Brake disc thickness
Standard: 10mm (0.3937 in)
Service limit: 8.4 mm (0.3307 in)

Rear Brake Pad Check
1.
Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value.

Pad thickness
- Standard: 10mm (0.3937 in)
- Service limit: 2.0mm (0.0787 in)

2.
Check that grease is applied, to sliding contact points and the pad and backing metal for damage.
Rear Brake Disc Runout Check
1.
Place a dial gauge about 5mm (0.2 in.) from the outer circumference of the brake disc, and measure the runout of the disc.

Brake disc runout
Limit: 0.05 mm (0.00197 in.) or less (new one)

2.
If the runout of the brake disc exceeds the limit specification, replace the disc, and then measure the runout again.

   
The brake pad wear indicator (C) and brake disc make a friction noise when brake pads are worn out below the service limit of 2.0 mm (B).

3.
If the runout exceeds the limit specification, install the brake disc after turning it 180° and then check the runout of the brake disc again.
4.
If the runout cannot be corrected by changing the position of the brake disc, replace the brake disc.
Installation
1.
Installation is the reverse of removal.
2.
Using a SST (09581-11000,09580-U100) when installing the brake caliper assembly.
[General]

[EPB]

3.
After installation, bleed the brake system.
(Refer to Brake System - "Brake System Bleeding")
(Refer to ESP (Electronic Stability Program) System - "ESP System Bleeding")
   
Do not hit piston end by hammer or prying directly against piston face with screwdriver to push in piston.
Using wood or used pad to protect piston end and pushing the wood or pad is recommended.
When spreading a piston, SST should be cover all area of piston end face.
Rear Disc Brake Components and Components Location
Components [General] 1. Guide rod bolt2. Bleed screw3. Caliper bracket4. Caliper body5. Inner pad shim6. Brake pad7. Pad retainer [EPB] 1. Guide rod bolt2. Bleed screw3. Caliper carrie ...

Stop Lamp Switch Components and Components Location
Components Location 1. Brake pedal member assembly2. Stop lamp switch3. Bolt4. Return spring5. Brake pedal assembly6. Locking plate ...

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