Hyundai Coupes/Sedans 1986-1993 Repair Guide

Brake Disc (Rotor)

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REMOVAL & INSTALLATION



Except 1989 Excel

See Figure 1



Click image to see an enlarged view

Fig. Fig. 1: Separating the hub from the halfshaft to remove the rotor

  1. Remove the center hub cap and halfshaft nut. Then raise the vehicle and support it safely. Allow the wheels to hang freely. Then remove the front wheel.
  2.  
  3. Remove the brake caliper without disconnecting the hydraulic line and suspend it out of the way with a piece of wire.
  4.  
  5. Disconnect the stabilizer bar and strut bar from the lower control arm.
  6.  
  7. Remove the halfshaft from the transaxle and press the halfshaft out of the hub using tool 09526-11001 or equivalent.
  8.  
  9. Unbolt and remove the hub and knuckle from the bottom of the strut and remove the hub and knuckle assembly from the vehicle.
  10.  
  11. Several special tools are required to press the hub and disc from the steering knuckle and to remount them. Use 09517-21600 or equivalent. Do not attempt to hammer the parts apart, or the bearing will be damaged. Install the arm of the special tool then the body onto the knuckle and tighten the nut manually. Using special tool 09517-21500, separate the hub from the knuckle. Pull the bearings out, noting their positions and direction of installation (smaller diameter inward).
  12.  
  13. Matchmark the relationship between the brake disc and hub. Then place the knuckle in a vise and separate the rotor from the hub by removing the attaching bolts.
  14.  

To install:
  1. Install the hub to the rotor and attaching bolts.
  2.  
  3. Install the hub and knuckle to the bottom of the strut.
  4.  
  5. Install the halfshaft to the transaxle.
  6.  
  7. Connect the stabilizer bar and strut bar to the lower control arm, if disconnected.
  8.  
  9. Install the brake caliper.
  10.  
  11. Install the halfshaft nut and center hub cap and halfshaft nut.
  12.  
  13. Install the front wheel and lower the vehicle.
  14.  
  15. Torque the hub nut to 145-188 ft. lbs. (200-260 Nm).
  16.  

1989 Excel
  1. Raise the vehicle and support safely.
  2.  
  3. Remove the wheel and tire assembly.
  4.  
  5. Remove the caliper and support aside. Do not disconnect the hydraulic lines.
  6.  
  7. Remove the disc retainer screw, if equipped, and remove the rotor from the hub.
  8.  
  9. Installation is the reverse of the removal procedure.
  10.  

INSPECTION



See Figure 2



Click image to see an enlarged view

Fig. Fig. 2: Measuring rotor disc runout and thickness

  1. Loosen the wheel nuts.
  2.  
  3. Raise the front end and support on jackstands.
  4.  
  5. Remove the front wheels.
  6.  
  7. Using a 0-1 inch micrometer or Vernier caliper measure the rotor thickness. Minimum allowable rotor thicknesses are as follows:
    1. 1986-87 Excel with Sumitomo brakes-13mm.
    2.  
    3. 1988-93 Excel and Scoupe-19mm.
    4.  
    5. Elantra-20mm.
    6.  
    7. Sonata (Mando and Bendix)-20mm.
    8.  

  8.  
  9. Mount a magnetic base dial indicator to the strut member and zero the indicator stylus on the face of the rotor. Rotate the rotor 360°deg; by hand and record the run-out. Maximum rotor disc run-out for all Excel, Elantra and Scoupe models is 0.15mm and 0.10mm for Sonata.
  10.  
  11. If the thickness and run-out do not meet specifications, replace the rotor.
  12.  

 
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