Hyundai Sonata: Front Disc Brake Repair procedures - Brake System - Brake SystemHyundai Sonata: Front Disc Brake Repair procedures

Removal
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, pad retainers (C) and brake pads (B) in the caliper bracket (A).

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

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

7.
Remove the front brake disc by loosening the screws (A).

Replacement
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 bracket (A).

3.
Use a SST (09581-2T100) when installing the brake caliper assembly.

   
Do not hit piston end by hammer or prying directly against piston face with screwdriver to push in piston.
4.
Down the caliper body(A) then tighten the guide rod bolt(B).

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

Inspection
Front 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

Front brake disc thickness
[GAMMA1.6 T-GDI / THETA2.4 GDI]
- Standard: 25mm (0.9842in)
- Service limit: 23.4mm (0.9212 in)
[THETA2.0 T-GDI]
- Standard: 28mm (1.1023 in)
- Service limit : 26.4mm (1.0393in)
[EPB]
- Standard: 28mm(1.10 in)
- Service limit: 26.4mm (1.0393in)

4.
If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle.

Front 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
[GAMMA1.6 T-GDI / THETA2.4 GDI]
- Standard: 11.5mm (0.4527 in)
- Service limit: 2.0mm (0.0787 in)
[THETA2.0 T-GDI]
- Standard: 10.5mm (0.4133 in)
- Service limit: 2.0mm (0.0787 in)
[EPB]
- Standard: 10.5mm (0.4133 in)
- Service limit: 2.0mm (0.0787 in)

   
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).

Front 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: 0.04 mm (0.00157 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.
3.
If the runout does not exceed 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.
Use a SST (09581-2T100) when installing the brake caliper assembly.

   
Do not hit piston end by hammer or prying directly against piston face with screwdriver to push in piston
3.
After installation, bleed the brake system.
(Refer to Brake System - "Brake System Bleeding")
(Refer to ABS - "ABS System Bleeding")
(Refer to ESP (Electronic Stability Program) System - "ESP System Bleeding")
    Front Disc Brake Components and Components Location
    Components 1. Guide rod bolt2. Bleed screw3. Caliper bracket 4. Caliper body5. Inner pad shim6. Brake pad7. Pad retainer ...

    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 ...

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