Hyundai Coupes/Sedans 1986-1993 Repair Guide

Cables

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REMOVAL & INSTALLATION



1986-89 Excel

See Figures 1 and 2



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Fig. Fig. 1: Parking brake components-1986-89 Excel



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Fig. Fig. 2: Brake shoe outer diameter-1986-88 Excel (dimension A)

  1. Block the front wheels, raise the rear of car and support it on jackstands.
  2.  
  3. Disconnect the brake cable at the parking brake lever (brakes released).
  4.  
  5. Remove the cable clamps inside the driver's compartment (two bolts).
  6.  
  7. Disconnect the clamps on the rear suspension arm.
  8.  
  9. Remove the rear brake drums and the brake shoes assemblies.
  10.  
  11. Disconnect the parking brake cable from the lever on the trailing (rear) brake shoe. Remove the brake cables.
  12.  

To install:
  1. Route, install and connect the new cables. Make certain the cables are routed flush with the floor and the cable protectors are properly positioned on the suspension arm.
  2.  
  3. Install the grommets as show in the illustration. Make certain that the grommets are facing in the right direction.
  4.  
  5. Install the rear suspension arm and driver's side cable clamps without twisting the cables.
  6.  
  7. On 1986-88 models, set the rear brake shoe outside diameter (dimension "A") to 179.0-179.5mm using the star wheel adjuster.
  8.  
  9. Adjust the parking brake and parking lever stroke. Check the operation of the parking brake and the parking brake switch.
  10.  

1990-93 Excel And Scoupe

See Figure 3



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Fig. Fig. 3: Parking brake components-1990-93 Excel and Scoupe

  1. Raise the vehicle and support it safely. Remove the rear wheels and brake drums.
  2.  
  3. Remove the console box and rear seat.
  4.  
  5. Release the hand brake and then disconnect the cable connectors at the equalizer. It may be necessary to loosen the cable adjusting nuts to do this.
  6.  
  7. Disconnect all cable clamps from the body. Remove the mounting bolts for the large mounting clamp located just forward of where the cables pass through the body grommets.
  8.  
  9. Pull the cables and grommets out of the body.
  10.  
  11. Disconnect the cables at the rear brakes.
  12.  

To install:
  1. When installing the cables, make sure the grommets are installed in the body completely and that the concave side faces to the rear. Adjust the hand brake mechanism. Adjust the switch for the indicator light so the light comes on when the lever is pulled 1 notch.
  2.  

Elantra

See Figure 4



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Fig. Fig. 4: Parking brake components-Elantra

  1. Raise the vehicle and support it safely.
  2.  
  3. Remove the rear console.
  4.  
  5. Detach the adjusting nut and detach the parking brake cable.
  6.  
  7. Remove the tire and wheel assembly, brake drum and the brake shoes.
  8.  
  9. Detach the parking brake cable from the parking brake lever.
  10.  
  11. Remove the parking brake cable retainer ring in the rear of the backing plate.
  12.  
  13. Remove the ear seat cushion assembly and roll up the carpet.
  14.  
  15. Loosen the parking brake cable clamp and remove the cable assembly.
  16.  

To install:
  1. Check the parking brake cables for left and right identification marks and install accordingly.
  2.  
  3. Install the cable to the parking brake lever. Move the adjuster lever all the way to the back when installing the shoe-to-shoe spring. Install the brake shoes and the drum.
  4.  
  5. Install the parking brake retainer ring to the rear of the backing plate. Install the cable into the vehicle and secure using the cable clamp. Install the rear seat cushion.
  6.  
  7. Connect the parking brake cable to the actuator assembly and adjust the lever stroke. Apply a thin coating of specified grease to the sliding parts of the ratchet plate and the ratchet paw.
  8.  
  9. Install the tire and wheel assembly.
  10.  
  11. Raise and support the vehicle safely.
  12.  
  13. Apply and then release the hand brake and rotate each rear wheel to make sure the brakes are not dragging.
  14.  

Sonata
WITH REAR DRUM BRAKES

See Figures 5, 6 and 7



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Fig. Fig. 5: Parking brake components-Sonata



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Fig. Fig. 6: Parking brake grommet installation-Sonata with rear drum brakes



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Fig. Fig. 7: Lubricate the parking brake ratchet plate and ratchet pawl sliding surfaces with multi-purpose grease

  1. Remove the main console.
  2.  
  3. Remove the cable adjuster, pin, equalizer bracket and nut holder.
  4.  
  5. Disconnect the parking brake switch connector.
  6.  
  7. Remove the parking brake lever.
  8.  
  9. Remove the rear seat cushion and lift up the carpet.
  10.  
  11. Remove the parking brake cable clamp and grommet.
  12.  
  13. Raise the rear end and remove the tires, drums and hub assemblies.
  14.  
  15. Remove the brake shoe assemblies.
  16.  
  17. Remove the cable clip.
  18.  
  19. Disconnect the cable from the trailing shoe.
  20.  
  21. From underneath the vehicle pull the cable out to remove it. Check the cables for wear, cracks in the cable casing and fraying in the cable ends. Check the parking brake lever ratchet for wear. If the cable grommets are worn or cracked, replace them.
  22.  

To install:

The cables are marked right and left, so make sure they are installed on their respective sides.

  1. Route the cable up through the under body and connect the cable to the trailing shoe. Install the cable clip.
  2.  
  3. Install the brake shoe assemblies. Set the adjuster lever all the way back when installing the shoe-to-shoe spring.
  4.  
  5. Install the hub, drum and tire assemblies. Lower the rear end.
  6.  
  7. Install the grommets as show in the illustration. Make certain that the grommets are facing in the right direction.
  8.  
  9. Replace the carpet and the rear seat cushion.
  10.  
  11. Install the parking brake lever and connect the parking brake switch.
  12.  
  13. Install the nut holder, equalizer bracket, pin and cable adjuster. Lubricate the ratchet plate and ratchet pawl sliding surfaces with multi-purpose grease.
  14.  
  15. Adjust the parking brake lever stroke.
  16.  
  17. Install the main console. Check the parking brake and parking brake switch for proper operation.
  18.  

WITH REAR DISC BRAKES
  1. Raise the rear and support safely. Remove the rear wheels.
  2.  
  3. Remove the rear caliper, rotor disc, hub and bearing assemblies.
  4.  
  5. Remove the lower shoe-to-shoe spring.
  6.  
  7. Remove the parking brake lever adjusters.
  8.  
  9. Remove the upper shoe-to-shoe return spring.
  10.  
  11. Disconnect the shoe hold down pin and spring.
  12.  
  13. Disconnect the cable clevis from the adjusting lever. Be careful not to tear cable dust boot. Pull the lever and slider assembly out towards the outboard side of the brake and through the access window in the backing plate.
  14.  
  15. Remove the cable clips.
  16.  
  17. Unbolt the backing plate from the suspension arm.
  18.  
  19. Loosen the cable adjusting nut and remove the cables from the adjuster bracket.
  20.  
  21. Remove the cables. Check the cables for wear, cracks in the cable casing and fraying in the cable ends. Check the parking brake lever ratchet for wear. If the cable grommets are worn or cracked, replace them. Check the dust boots for rips and tears. Check the brake shoe linings for wear and oil contamination. Minimum brake lining thickness is 2mm. Check the shoe webs and adjusters for bending. Check the return springs for bent hooks, over-extension and breaks. Check the lever and slider assemblies for cracks, bending and wear. Check the drum surface for scoring, wear and oil contamination. Replace any worn or damaged component as necessary.
  22.  

To install:
  1. Mount the backing plate to the suspension flange and torque the bolts in a diagonal pattern to 45-60 ft. lbs.
  2.  
  3. Lubricate the area between the lever and slider and where the slider contacts the backing plate. Use multi-purpose grease.
  4.  
  5. Install the lever and slider assembly through the window in the backing plate. Be careful not damage the dust boot. The lever should be positioned with the long portion into the backing plate first and then the indent for the cable clevis facing toward the rear of the vehicle last. The slider should be positioned on top of the lever. Lubricate the slider with multipurpose grease for easy rotation. The long arm of the slider should be positioned on the rear of the backing plate. The assembly should slide and rotate freely. Connect the cable clevis to the lever indent.
  6.  
  7. Install the brake shoes and shoe holddown pin.
  8.  
  9. Shorten the adjuster assembly and install between the slots in the bottom portion of the shoes.
  10.  
  11. Install the upper and lower shoe-to-shoe springs. The upper portion of the shoe web should contact the anchor block. Adjust the cable as necessary to make this contact.
  12.  
  13. Check the lever function by pushing the end of the lever by the cable clevis and observe the movement of the brake shoes. The tab end of the lever should move against the shoe and the slider tab end should contact fully against the outer shoe.
  14.  
  15. Install the parking brake adjusters.
  16.  
  17. Install the rear hub and bearing, rotor disc and caliper assemblies.
  18.  
  19. Mount the rear wheels and lower the vehicle.
  20.  
  21. Adjust the parking brake lever stroke. Check the parking brake and parking brake switch for proper operation. Lubricate the ratchet plate and ratchet pawl sliding surfaces with multi-purpose grease.
  22.  

LEVER STROKE ADJUSTMENT



1986-89 Excel

See Figure 8



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Fig. Fig. 8: Parking brake adjuster points-1986-89 Excel

  1. Fully release the brake lever.
  2.  
  3. Pull the parking brake upward with normal effort. Maximum travel should be 5-7 clicks. If not, proceed with the following steps:
  4.  
  5. Remove the floor console, pull back the carpeting and adjust the lever travel by turning the adjusting nuts on the cable ends. Adjust the right and left cables so that when the lever is pulled the cables are equal in length. If the cables are adjusted too tight, the adjuster lever will not engage the adjuster and the automatic shoe clearance adjuster mechanism will not work.
  6.  
  7. Loosen the parking brake switch mounting bolt. Adjust the switch so that when the lever is fully released, the switch lamp goes and out and when the lever is pulled one click, the switch lamp illuminates. If the switch does not operate as described check the switch lamp bulb. If the bulb is good, replace the switch.
  8.  
  9. After the adjustment, make sure that the rear brakes do not drag when the parking brake lever is released.
  10.  
  11. Install the main console.
  12.  

1990-93 Excel, Elantra, Scoupe And Sonata

See Figures 9 and 10



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Fig. Fig. 9: Parking brake adjusting nut-1990-93 Excel, Elantra and Scoupe



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Fig. Fig. 10: Parking brake cable adjustment nut-Sonata

  1. Fully release the brake lever.
  2.  
  3. Pull the parking brake upward with normal effort. Maximum travel should be 8-9 clicks on Sonata and 8-9 clicks on 1990 Excel.
  4.  
  5. If not, proceed with the following steps:
  6.  
  7. Remove the front console and adjust the cable length by turning the nut on the equalizer.
  8.  
  9. Loosen the parking brake switch mounting bolt. Adjust the switch so that when the lever is fully released, the switch lamp goes and out and when the lever is pulled one click, the switch lamp illuminates. If the switch does not operate as described check the switch lamp bulb. If the bulb is good, replace the switch.
  10.  
  11. After the adjustment, make sure that the rear brakes do not drag when the parking brake lever is released.
  12.  
  13. Install the main console.
  14.  

 
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