Hyundai Coupes/Sedans 1994-1998 Repair Guide

Brake Disc (Rotor)

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REMOVAL & INSTALLATION



See Figures 1 through 8



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Fig. Fig. 1: To remove the entire caliper assembly, loosen the carrier bolts



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Fig. Fig. 2: When removing the rotor it may be easier to remove the caliper and carrier as an assembly



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Fig. Fig. 3: The rotor is attached to the hub and can not be removed without removing the hub first



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Fig. Fig. 4: Attach a gear puller to hub using lug nuts



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Fig. Fig. 5: Place the center bolt of the puller on the axle shaft and press the hub and disc from the axle shaft



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Fig. Fig. 6: The backing plate may now be removed for servicing or cleaning



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Fig. Fig. 7: Remove the hub to rotor bolts....



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Fig. Fig. 8: ....and separate the hub and rotor

Front Rotor
  1. Raise and support the vehicle safely.
  2.  
  3. Remove the wheels.
  4.  
  5. Remove the brake caliper and carrier without disconnecting the hydraulic line and suspend it out of the way with a piece of mechanic-s wire.
  6.  
  7. Remove the axle shaft nut.
  8.  
  9. Using special tool (PN 09526-11001) or equivalent press the hub and disc from the axle shaft.
  10.  
  11. Matchmark the relationship between the brake disc and hub.
  12.  
  13. Remove the bolts attaching the rotor to the hub.
  14.  
  15. Remove the rotor.
  16.  

To install:
  1. Align and install the hub on the rotor. Tighten attaching bolts to 36-43 ft. lbs. (50-60 Nm).
  2.  
  3. Install the hub on the spindle.
  4.  
  5. Tighten the axle shaft nut while spinning the hub to the following torque:

    Tiburon-143-164 ft. lbs. (200-230 Nm)
     
    Sonata-146-189 ft. lbs. (200-260 Nm)
     
    Accent and 1996-98 Elantra-130-159 ft. lbs. (180-220 Nm)
     
    1994-95 Elantra-108-145 ft. lbs. (150-200 Nm)
     

  6.  
  7. Install the brake caliper.
  8.  
  9. Install the wheels.
  10.  
  11. Lower the vehicle.
  12.  

Rear Rotor
  1. Raise and support the vehicle safely.
  2.  
  3. Remove the wheels.
  4.  
  5. Remove the brake caliper.
  6.  
  7. Remove the rotor set
  8.  
  9. Remove the rotor.
  10.  

To install:
  1. Install the rotor and tighten the set screw securely.
  2.  
  3. Install the brake caliper.
  4.  
  5. Install the front wheel.
  6.  
  7. Lower the vehicle.
  8.  

INSPECTION



See Figure 9



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Fig. Fig. 9: 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.
  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 degrees by hand and record the run-out
  10.  
  11. Compare measurements to the brake specifications chart. If the thickness and run-out do not meet specifications, replace the rotor.
  12.  

 
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