Hyundai Kona: Brake System / Brake Pad Repair procedures

Replacement
Front Brake Pad
1.
Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2.
Remove the front wheel and tire (A) from front hub.
Tightening torque :
107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb-ft)
  
Be careful not to damage the hub bolts when removing the front wheel and tire (A).

3.
Remove the parking brake cable fixing clip (A).
Tightening torque :
8.8 - 13.7 N.m (0.9 - 1.4 kgf.m, 6.5 - 10.1 lb-ft)

4.
Down the caliper body (A) by loosening the guided rod bolt.

5.
Remove the pad return spring (A).

6.
Remove the brake pad (A).

7.
Replace the pad retainer (A) with a new one.

8.
Replace the brake pad (A) with a new one.

  
When installing, use a new one return spring (A), pad retainer (B), inner shim (C).

9.
Install the pad return spring (A).

  
Pad return springs must be replaced with new ones whenever pads are replaced.
Technicians should be careful not to deform pad return springs.
When pad return springs are deformed, it may cause improper braking, more fuel consumption.
10.
Apply The Anti-noise grease. (Only Front 17" Brake)
Grease Specification : Daikalub 528D
Item
Caliper finger
Quantity
min. 0.4g
Location


  
Pad mold and disc surface must be free from grease.
11.
Use a SST (09581-2T100) when installing the brake caliper assembly.
  
Connect an air hose (B) to the SST after confirming that the valve of the SST is surely closed.
Input the SST in the caliper and press the caliper piston while opening the valve of the SST slowly couter clock wise.
Close the valve (A) of the SST and disconnect the air hose (B); then, open the valve again to get the rest of air out and remove the SST from the caliper.

12.
Install the caliper body (A) then tighten the guide rod bolt.
Tightening torque :
21.6 - 31.4 N.m (2.2 - 3.2 kgf.m, 15.9 - 23.1 lb-ft)

13.
Install the front wheel and tire (A).
  
Be careful not to damage the hub bolts when removing the front wheel and tire (A).
Tightening torque :
107.8 - 127.4 N.m (11.0 - 13.0 kgf.m, 79.5 - 94.0 lb-ft)

Rear Brake Pad
1.
Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2.
Remove the rear wheel and tire (A) from the rear hub.
  
Be careful not to damage the hub bolts when removing the rear wheel and tire (A).

3.
Remove the parking brake cable fixing clip (A).

4.
Pull the operation lever as a clock-wise direction and then remove the parking cable (A) from the caliper.

5.
Up the caliper body (A) by loosening the guided rod bolt.

6.
Remove the pad return spring (A).

7.
Remove the brake pad (A).

8.
Replace the pad retainer (A) with a new one.

9.
Replace the brake pad (A) with a new one.

  
When installing, use a new one return spring (A), pad retainer (B), inner shim (C). brake pad (D).

10.
Install the pad return spring (A).

  
Pad return springs must be replaced with new ones whenever pads are replaced.
Technicians should be careful not to deform pad return springs.
When pad return springs are deformed, it may cause improper braking, more fuel consumption.
11.
Install the caliper body (A) and then tighten the guide rod bolt.

12.
Install the caliper body (A) then tighten the guide rod bolt.
Tightening torque :
21.6 - 31.4 N.m (2.2 - 3.2 kgf.m, 15.9 - 23.1 lb-ft)

13.
Pull the operation lever as a clock-wise direction and install the parking cable (A) from the caliper.

14.
Install the parking brake cable fixing clip (A).

15.
Install the wheel and tire (A).
Tightening torque :
107.9 - 127.5 N.m (11.0 - 13.0 kgf.m 79.6 - 94.0 lb-ft)
  
When installing, press and rotate the piston into the caliper body until it is fully retracted.

Inspection
Front Brake Pad Check
1.
Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value.
Front brake disc thickness Pad thickness
- Standard : 11 mm (0.43 in) or 11.5 mm (0.45 in)
- Service Limit : 2.0 mm (0.78 in)

2.
Check that grease is applied, to sliding contact points and the pad and backing metal for damage.
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 value : 9 mm (0.35 in)
- Service limit : 2.0 mm (0.0787 in)
2.
Check the damage of pad, backing metal and contamination with grease.
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