Hyundai Coupes/Sedans 1986-1993 Repair Guide

Disc Brake Pads

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INSPECTION



See Figures 1 and 2

The inner brake pads are equipped with metal wear indicators which act as warning devices to alert the driver to change the brake pads. When the brake pad wears to the minimum service limit, the indicator contacts the rotor and makes a noticeable "chirping" noise while the wheels are turning. When you here this sound, it's time to replace the front pads.

To perform a visual inspection, do the following:

  1. Loosen the front lug nuts.
  2.  
  3. Raise the front end and support safely.
  4.  
  5. Remove the front wheels.
  6.  
  7. Check the brake lining thickness through the inspection window in the caliper with a 6 in. machinist's rule. After checking the brake lining thickness check the brake pads for oil deposits, and check the pad springs for wear and damage. Make replacements as necessary.
  8.  



Click image to see an enlarged view

Fig. Fig. 1: Brake pad wear indicators alert the driver of brake pad wear



Click image to see an enlarged view

Fig. Fig. 2: To inspect the brake pads, look through the end of the caliper

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! There are solvents made for the purpose of cleaning brake parts.

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. On later models, a Tokico system is used.

SUMITOMO FRONT DISC BRAKES

See Figures 3, 4 and 5

  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the front wheels.
  4.  
  5. Pry off the dust shield from the caliper.
  6.  



Click image to see an enlarged view

Fig. Fig. 3: Removing the dust shield from the caliper-early Excel with Sumitomo front caliper

  1. Depress the center of the outboard spring clip and remove the clip by slipping the ends from the pins.
  2.  



Click image to see an enlarged view

Fig. Fig. 4: Removing the spring clips from the caliper pins-early Excel with Sumitomo front caliper

  1. Remove the inboard spring clip with pliers.
  2.  



Click image to see an enlarged view

Fig. Fig. 5: Removing the caliper pins-early Excel with Sumitomo front caliper

  1. Using pliers, pull the retaining pins from the caliper.
  2.  
  3. Lift the pads and anti-squeal shims from the caliper.
  4.  
  5. Clean all caliper parts, especially the torque plate shafts, with a solvent made for brake parts.
  6.  


CAUTION
Replace all brake pads at the same time. Never replace the pads on one wheel only.

  1. If the dust protector or spring clips are weak, damaged or deformed, replace them.
  2.  
  3. Remove the cap from the master cylinder reservoir and, using a clean suction gun, remove about 6mm of fluid.
  4.  
  5. Using a C-clamp, force the caliper piston back into the caliper as far as it will go.
  6.  

If the anti-squeal shims are at all rusted or deformed, discard them and use an anti-squeal compound, available at most auto parts stores. Furthermore, the anti-squeal shims may not be usable with some aftermarket brake pads due to thicker linings. The shims may preclude the proper fit of these pads. In that case, discard the shims and use the anti-squeal compound.

  1. Install the inboard pad and anti-squeal shim.
  2.  
  3. Install the outboard pad and anti-squeal shim.
  4.  
  5. Install the pins.
  6.  
  7. Install the two spring clips.
  8.  
  9. Install the dust shield.
  10.  
  11. Install the wheels and lower the car. Get in the car and depress the brake pedal a few times. The first couple of strokes on the pedal will feel overly long. However, the pads will set themselves and the stroke will return to normal.
  12.  

1988-93 Excel and Scoupe
  1. Raise the vehicle and support it safely.
  2.  
  3. Remove the front wheels.
  4.  
  5. Pry off the dust shield from the caliper.
  6.  
  7. Depress the center of the outboard spring clip and remove the clip by slipping the ends from the pins.
  8.  
  9. Remove the inboard spring clip with pliers.
  10.  
  11. Using pliers, pull the retaining pins from the caliper.
  12.  
  13. Lift the pads and anti-squeal shims from the caliper.
  14.  
  15. Clean all caliper parts, especially the torque plate shafts, with a solvent made for brake parts.
  16.  

Replace all brake pads at the same time. Never replace the pads on 1 wheel only.

  1. If the dust protector or spring clips are weak, damaged or deformed, replace them.
  2.  
  3. Remove the cap from the master cylinder reservoir and, using a clean suction gun, remove about 6mm of fluid.
  4.  

To install:
  1. Using a C-clamp, force the caliper piston back into the caliper as far as it will go.
  2.  
  3. Install the inboard pad and anti-squeal shim.
  4.  
  5. Install the outboard pad and anti-squeal shim.
  6.  
  7. Install the pins.
  8.  
  9. Install the spring clips.
  10.  
  11. Install the dust shield.
  12.  
  13. Install the wheels and lower the vehicle. Depress the brake pedal a few times. The first couple of strokes on the pedal will feel overly long. However, the pads will set themselves and the stroke will return to normal.
  14.  

Elantra
  1. Raise the vehicle and support it safely.
  2.  
  3. Remove the front wheel and tire assemblies.
  4.  
  5. Remove the 2 bolts from the torque plate and lift off the caliper. Suspend the caliper safely with wire. Don't stretch the brake hose.
  6.  
  7. Remove the pads and anti-rattle clips from the caliper.
  8.  
  9. Remove the cap from the master cylinder reservoir and siphon off about 1 / 3 of the fluid.
  10.  

To install:
  1. Using a large C-clamp, press the piston all the way back into the caliper.
  2.  
  3. Install the new pads and clips. Position the pad with the wear sensor on the piston side and upwards.
  4.  
  5. Position the caliper and install the bolts. Torque the bolts to 23 ft. lbs. (32 Nm).
  6.  

Sonata

The Sonata is equipped with two types of front disc brakes: Mando and Bendix.

Mando front disc brakes are used on 4 and 6 cylinder Sonatas equipped with rear drum brakes.

Bendix front disc brakes are used on V6 Sonatas equipped with rear disc brakes.

MANDO FRONT DISC BRAKES
  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the front wheels.
  4.  
  5. Remove the 2 caliper guide rod bolts and raise the caliper up and out of the way. Tie the caliper assembly off to a suspension member with a piece of string.
  6.  
  7. Lift the pads and anti-squeal shims from the caliper.
  8.  
  9. Depress the center of the outboard spring clip and remove the clip by slipping the ends from its anchors.
  10.  
  11. Remove the inboard spring clip with pliers.
  12.  
  13. Clean all caliper parts, especially the torque plate shafts, with a solvent made for brake parts.
  14.  


CAUTION
Replace all brake pads at the same time. Never replace the pads on one wheel only.

  1. If the spring clips are weak, damaged or deformed, replace them.
  2.  
  3. Remove the cap from the master cylinder reservoir and, using a clean suction gun, remove about 6mm of fluid.
  4.  
  5. Install the pad clips.
  6.  
  7. Install the pads onto each clip.
  8.  

Position the inner pad so that the pad wear indicator is facing toward the piston side and up.

  1. Using a C-clamp or a piece of wood, force the caliper piston back into the caliper as far as it will go.
  2.  
  3. Untie the caliper and install the guide bolts. Torque the bolts to 16-23 ft. lbs.
  4.  
  5. Install the wheels and lower the car. Get in the car and depress the brake pedal a few times. The first couple of strokes on the pedal will feel overly long. However, the pads will set themselves and the stroke will return to normal.
  6.  

BENDIX FRONT DISC BRAKES
  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the front wheels.
  4.  
  5. Remove the small retaining pin from the bottom of the caliper. This pin must be replaced whenever the front pads are replaced.
  6.  
  7. Rotate the caliper on the large locating pin until the brake pads are accessible.
  8.  


CAUTION
DO NOT remove the locating pin from the caliper. This pin is sealed for life and exposure to dust or dirt will cause it to fail prematurely.

  1. Lift the pads and anti-squeal spring from the caliper.
  2.  
  3. Clean all caliper parts, especially the torque plate shafts, with a solvent made for brake parts.
  4.  
  5. Remove the cap from the master cylinder reservoir and, using a clean suction gun, remove about 6mm of fluid.
  6.  
  7. Using a C-clamp, a piece of wood, or special tool 09581-11000, force the caliper piston back into the caliper as far as it will go.
  8.  
  9. Install the pads and anti-rattle spring.
  10.  

Position the inner pad so that the pad wear indicator is facing toward the large caliper pin.

  1. Swing the caliper upward and install a new small retaining pin.
  2.  
  3. Add brake fluid to the fluid reservoir until the full line is reached.
  4.  
  5. Install the wheels and lower the car. Get in the car and depress the brake pedal a few times. The first couple of strokes on the pedal will feel overly long. However, the pads will set themselves and the stroke will return to normal. Replenish the master cylinder fluid reservoir as necessary.
  6.  

 
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