Hyundai Coupes/Sedans 1994-1998 Repair Guide

Brake Calipers

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REMOVAL & INSTALLATION



See Figures 1 through 8



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Fig. Fig. 1: On rear calipers, use special tool (PN 09580-34000) or equivalent, to screw the caliper back into the piston



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Fig. Fig. 2: Align the rear caliper piston mating mark as illustrated



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Fig. Fig. 3: Remove dirt from the brake hose fitting prior to disconneting the brake hose



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Fig. Fig. 4: Loosen the brake hose banjo bolt....



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Fig. Fig. 5: ....and disconnect the hose. Replace the washers during assembly



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Fig. Fig. 6: Remove the caliper bolt(s) and lift the caliper out of the way



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Fig. Fig. 7: Disconnect the dust boot from the caliper



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Fig. Fig. 8: Some calipers use only one attaching bolt. The top of the caliper is positioned by a stud attached to the carrier

Front Calipers
  1. Raise and support the vehicle safely.
  2.  
  3. Remove the wheels.
  4.  
  5. Remove the brake pads and clips.
  6.  
  7. Remove some of the brake fluid in the reservoir. This prevents the reservoir from overflowing when the caliper piston is retracted.
  8.  
  9. Use a large C-clamp to retract the piston into the caliper.
  10.  
  11. If the caliper is to be replaced, disconnect and cap the brake hose at the caliper.
  12.  
  13. If the caliper is not being replaced, suspend the caliper out of the way using mechanic's wire
  14.  
  15. Loosen the caliper bolt(s) and lift the caliper out of the way.
  16.  

To install:
  1. Install the brake pads and clips on the carrier.
  2.  
  3. Position the caliper and tighten caliper bolts to 16-23 ft. lbs. (22-32 Nm).
  4.  
  5. Install the brake hose and tighten to 18-22 ft. lbs. (25-30 Nm).
  6.  
  7. Install the wheels.
  8.  
  9. Lower the vehicle.
  10.  
  11. Bleed the brakes
  12.  

Rear Calipers
  1. Raise and support the vehicle safely.
  2.  
  3. Remove the wheels.
  4.  
  5. Remove the brake pads and clips.
  6.  
  7. Remove some of the brake fluid in the reservoir. This prevents the reservoir from overflowing when the caliper piston is retracted.
  8.  
  9. Use special tool (PN 09580-34000), or equivalent, to screw the piston back into the caliper. Align the caliper piston mating mark as illustrated.
  10.  
  11. If the caliper is to be replaced, disconnect and cap the brake hose at the caliper. Disconnect the parking brake cable.
  12.  
  13. If the caliper is not being replaced, suspend the caliper out of the way using mechanic's wire
  14.  
  15. Loosen the caliper bolt(s) and lift the caliper out of the way.
  16.  

To install:
  1. Install the brake pads and clips on the carrier.
  2.  
  3. Position the caliper and tighten caliper bolts to 16-23 ft. lbs. (22-32 Nm).
  4.  
  5. Install the brake hose and tighten to 18-22 ft. lbs. (25-30 Nm). Connect the parking brake cable.
  6.  
  7. Install the wheels.
  8.  
  9. Lower the vehicle.
  10.  
  11. Bleed the brakes
  12.  

OVERHAUL



See Figures 9 through 16

Some vehicles may be equipped dual piston calipers. The procedure to overhaul the caliper is essentially the same with the exception of multiple pistons, O-rings and dust boots.

  1. Remove the caliper from the vehicle and place on a clean workbench.
  2.  


CAUTION
NEVER place your fingers in front of the pistons in an attempt to catch or protect the pistons when applying compressed air. This could result in personal injury!

Depending upon the vehicle, there are two different ways to remove the piston from the caliper. Refer to the brake pad replacement procedure to make sure you have the correct procedure for your vehicle.

  1. The first method is as follows:
    1. Stuff a shop towel or a block of wood into the caliper to catch the piston.
    2.  
    3. Remove the caliper piston using compressed air applied into the caliper inlet hole. Inspect the piston for scoring, nicks, corrosion and/or worn or damaged chrome plating. The piston must be replaced if any of these conditions are found.
    4.  

  2.  



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Fig. Fig. 9: For some types of calipers, use compressed air to drive the piston out of the caliper, but make sure to keep your fingers clear



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Fig. Fig. 10: Withdraw the piston from the caliper bore

  1. For the second method, you must rotate the piston to retract it from the caliper.
  2.  
  3. If equipped, remove the anti-rattle clip.
  4.  



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Fig. Fig. 11: On some vehicles, you must remove the anti-rattle clip

  1. Use a pry par to remove the caliper boot, being careful not to scratch the housing bore.
  2.  



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Fig. Fig. 12: Use a pry bar to carefully pry around the edge of the boot ...



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Fig. Fig. 13: ... then remove the boot from the caliper housing, taking care not to score or damage the bore

  1. Remove the piston seals from the groove in the caliper bore.
  2.  



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Fig. Fig. 14: Use extreme caution when removing the piston seal; DO NOT scratch the caliper bore

  1. Carefully loosen the brake bleeder valve cap and valve from the caliper housing.
  2.  
  3. Inspect the caliper bores, pistons and mounting threads for scoring or excessive wear.
  4.  
  5. Use crocus cloth to polish out light corrosion from the piston and bore.
  6.  
  7. Clean all parts with denatured alcohol and dry with compressed air.
  8.  

To assemble:
  1. Lubricate and install the bleeder valve and cap.
  2.  
  3. Install the new seals into the caliper bore grooves, making sure they are not twisted.
  4.  
  5. Lubricate the piston bore.
  6.  
  7. Install the pistons and boots into the bores of the calipers and push to the bottom of the bores.
  8.  
  9. Use a suitable driving tool to seat the boots in the housing.
  10.  



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Fig. Fig. 15: Use the proper size driving tool and a mallet to properly seal the boots in the caliper housing

  1. Install the caliper in the vehicle.
  2.  
  3. Install the wheel and tire assembly, then carefully lower the vehicle.
  4.  
  5. Properly bleed the brake system.
  6.  



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Fig. Fig. 16: There are tools, such as this Mighty-Vac, available to assist in proper brake system bleeding

 
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