Hyundai Kona: Brake System / Rear Disc Brake Repair procedures

Removal
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.
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 rear wheel and tire (A).

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

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

5.
Loosen the guide rod bolts and then remove the caliper body (A).
Tightening torque :
21.6 - 31.4 N.m (2.2 - 3.2 kgf.m, 15.9 - 23.1 lb-ft)

6.
Remove 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.
7.
Remove the brake pad (A).

8.
Remove the pad retainer (A).

9.
Loosen the caliper mounting bolts and then remove the caliper carrier (A).
Tightening torque :
63.7 - 73.5 N.m (6.5 - 7.5 kgf.m, 47.0 - 54.2 lb-ft)

10.
Loosen the screw and then remove the brake disc (A).
Tightening torque :
4.9 - 5.9 N.m (0.5 - 0.6 kgf.m, 3.6 - 4.3 lb-ft)

Replacement
Guide rod pin and boot
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 counterclock-wise direction and then parking cable (A) from the caliper.

5.
Loosen the guide rod bolt and then up the caliper body (A).

6.
Replace the guide rod and boot (A) with a new one.

  
Pad return springs must be replaced with new ones whenever pads are replaced.
Technicians should be careful not to deform pad return springs.
Specified grease : GREASE BG-1 (MG511-60)
Amount : 0.35 - 0.8g
When pad return springs are deformed, it may cause improper braking, more fuel consumption.
7.
Install the caliper body (A)
Tightening torque :
21.6 - 31.4 N.m (2.2 - 3.2 kgf.m, 15.9 - 23.1 lb-ft)

8.
Install the rear wheel and tire (A).
Tightening torque :
107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb-ft)

Installation
1.
To install, reverse the removal procedure.
2.
When istalling, press and rotate the piston into the caliper body until it is fully retracted.

  
Wind the piston into the caliper body until it is fully retracted.
Do not use any power assisted tools for this task.
3.
After installing, bleed the brake system.
(Refer to Brake System - "Brake System Bleeding")
(Refer to Brake System - "ABS System Bleeding")
(Refer to Brake System - "ESP System Bleeding")
Inspection
Rear Brake Disc Thickness Check
1.
Check the brake disc for damage and cracks.
2.
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 : 10 mm (0.394 in)
- Service limit (2WD) : 8.4 mm (0.33 in)
- Service limit (4WD) : 8.0 mm (0.31 in)
- Deviation : less than 0.01 mm (0.0003 in)

3.
If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle.
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 : 0.04 mm (0.0016 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 cannot be corrected by changing the position of the brake disc, replace the brake disc.
Adjustment
  
Re-setting of the parking brake is necessary after overhauling the caliper body, or if the brake calipers, housing, parking brake cable or brake discs have been changed.
1.
Remove the floor console to reach the adjusting nut.
2.
Loosen the parking brake cable until both operating levers rest in fully off position.
3.
Bring the brake pads in their operating position by pressing the brake pedal down several times until there is resistance.
4.
Tension the parking brake cable by tightening the adjusting nut, until the operating levers on both calipers lift from the stop, up to a distance of (A) and (D) between operating lever (B) and stopper (C).
Distance (A + D) : Max. 3 mm (0.12 in)

5.
Refit the floor console.
6.
Parking brake lever in the car must be in fully loosened position.
7.
If the handbrake cables where changed, actuate the parking brake a few times with maximum force to stretch the parking brake cables, and then control adjusting as above.
8.
Check the wheels of their free operation.
9.
Test drive.
Rear Disc Brake Components and components location
Components 1. Brake pad 2. Guide rod pin 3. Guide rod pin boot 4. Caliper carrier 5. Pad retainer 6. Brake pad 7. Pad return spring ...

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