Hyundai Coupes/Sedans 1986-1993 Repair Guide

Brake Calipers

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REMOVAL & INSTALLATION




CAUTION
Brake linings contain asbestos. Asbestos is a known cancer-causing agent. When working on brakes, remember that the dust which accumulates on the brake parts and/or in the drum contains asbestos. Always wear a protective face covering, such as a painter's mask, when working on the brakes. NEVER blow the dust from the brakes or drum.

1986-87 Excel

On Excels with manual transmissions produced up to December of 1987 and on Excels with automatic transmissions produced up to February of 1987, a Sumitomo type front disc system is used. Later models use a Tokico system.

SUMITOMO CALIPER
  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the wheels.
  4.  
  5. Remove the brake pads as described above.
  6.  
  7. Loosen the brake line at the caliper.
  8.  

Have some kind of capping device handy to plug the brake line once it is disconnected.

  1. Remove the caliper/torque plate mounting bolts. Lift off the caliper. Hold the brake line and unscrew the caliper. Plug the line to prevent the system from draining.
  2.  

To install:
  1. Support the brake line and connect it to the caliper. Position the caliper onto its mounting and install the mounting bolts. Use new lock tabs under the bolt heads. Torque the mounting bolts to 58 ft. lbs.; the brake hose to 11 ft. lbs.
  2.  
  3. Install the brake pads.
  4.  
  5. Bleed the system.
  6.  
  7. Install the front wheels. Lower the vehicle.
  8.  

1988-93 Excel, Elantra and Scoupe
  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the front wheels.
  4.  
  5. Loosen the brake line at the caliper and disconnect it.
  6.  

Have some kind of capping device handy to plug the brake line once it is disconnected.

  1. Remove the brake pads as described above.
  2.  
  3. Remove the pin and sleeve boots.
  4.  
  5. Remove the lower caliper bolt and raise the caliper up and out to remove it.
  6.  

To install:
  1. Position the caliper onto its mounting and install the lower mounting bolt. Torque the bolt to 16-23 ft. lbs. (22-32 Nm).
  2.  
  3. Install the pin boots, sleeve boots and brake pads.
  4.  
  5. Connect the brake line to the caliper with two new metal gaskets. Torque the brake line union bolt to 11 ft. lbs.
  6.  
  7. Bleed the system.
  8.  
  9. Mount the front wheels and lower the vehicle.
  10.  

Sonata
MANDO CALIPER
  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the front wheels.
  4.  
  5. Loosen the brake line at the caliper and disconnect it.
  6.  

Have some kind of capping device handy to plug the brake line once it is disconnected.

  1. Remove the two caliper guide rod bolts from the torque plate and raise the cylinder up and out to remove it.
  2.  

To install:
  1. Mount the caliper and install the two guide bolts. Torque the bolts to 16-23 ft. lbs.
  2.  
  3. Connect the brake line to the caliper and tighten the fitting to 9-12 ft. lbs.
  4.  
  5. Bleed the system.
  6.  
  7. Mount the front wheels and lower the vehicle.
  8.  

BENDIX CALIPER
  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the front wheels.
  4.  
  5. Disconnect the brake tube from the brake hose. Release the brake hose clip and remove the brake hose from the strut.
  6.  

Have some kind of capping device handy to plug the brake line once it is disconnected.

  1. Loosen and disconnect the brake line from the caliper.
  2.  
  3. Remove the small retaining pin from the lower part of the caliper.
  4.  
  5. Swing the caliper up until it clears the rotor and pads.
  6.  
  7. Slide the caliper inboard until the locating pin disengages from it's groove in the caliper. Pull the caliper from the locating pin.
  8.  
  9. Inspect the locating pin for wear and damage. Replace the pin as required. Protect the pin from exposure to dirt and dust, If the pin is contaminated it will wear prematurely and eventually fail. Inspect the anchor plate for wear and damage.
  10.  

To install:
  1. Lubricate the locating pin bore with white silicone compound. Mount the caliper onto the locating pin. Push the caliper firmly onto the pin making sure that the pin snaps into the caliper groove. Lower the caliper until the small retaining pin holes are aligned. Install a new retaining pin into the lower part of the caliper. Tighten the pin.
  2.  

 
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