Hyundai Coupes/Sedans 1994-1998 Repair Guide

Wheel Cylinders

Print

REMOVAL & INSTALLATION



See Figures 1, 2 and 3



Click image to see an enlarged view

Fig. Fig. 1: Disconnect the brake line at the wheel cylinder. Always use a flare nut wrench to prevent rounding the fitting



Click image to see an enlarged view

Fig. Fig. 2: Remove the wheel cylinder attaching bolts....



Click image to see an enlarged view

Fig. Fig. 3: ....and remove the wheel cylinder from the backing plate

  1. Remove the brake shoes.
  2.  
  3. Place a container or some old rags under the brake backing plate to catch the brake fluid that will run out of the wheel cylinder.
  4.  
  5. Disconnect and plug the brake line.
  6.  
  7. Remove the wheel cylinder mounting bolts.
  8.  
  9. Remove the wheel cylinder from the backing plate.
  10.  

To Install:
  1. Install the wheel cylinder on the backing plate and tighten mounting bolts to 108-156 inch lbs (7-10 Nm).
  2.  
  3. Connect the brake line and tighten fitting to 9-12 ft. lbs. (13-17 Nm).
  4.  
  5. Install brake shoes.
  6.  
  7. Refill and bleed the system.
  8.  

OVERHAUL



See Figures 4 through 13

Wheel cylinder overhaul kits may be available, but often at little or no savings over a reconditioned wheel cylinder. It often makes sense with these components to substitute a new or reconditioned part instead of attempting an overhaul.

If no replacement is available, or you would prefer to overhaul your wheel cylinders, the following procedure may be used. When rebuilding and installing wheel cylinders, avoid getting any contaminants into the system. Always use clean, new, high quality brake fluid. If dirty or improper fluid has been used, it will be necessary to drain the entire system, flush the system with proper brake fluid, replace all rubber components, then refill and bleed the system.

  1. Remove the wheel cylinder from the vehicle and place on a clean workbench.
  2.  
  3. First remove and discard the old rubber boots, then withdraw the pistons. Piston cylinders are equipped with seals and a spring assembly, all located behind the pistons in the cylinder bore.
  4.  



Click image to see an enlarged view

Fig. Fig. 4: Remove the outer boots from the wheel cylinder

  1. Remove the remaining inner components, seals and spring assembly. Compressed air may be useful in removing these components. If no compressed air is available, be VERY careful not to score the wheel cylinder bore when removing parts from it. Discard all components for which replacements were supplied in the rebuild kit.
  2.  



Click image to see an enlarged view

Fig. Fig. 5: Compressed air can be used to remove the pistons and seals



Click image to see an enlarged view

Fig. Fig. 6: Remove the pistons, cup seals and spring from the cylinder

  1. Wash the cylinder and metal parts in denatured alcohol or clean brake fluid.
  2.  



Click image to see an enlarged view

Fig. Fig. 7: Use brake fluid and a soft brush to clean the pistons ...



Click image to see an enlarged view

Fig. Fig. 8: ... and the bore of the wheel cylinder


WARNING
Never use a mineral-based solvent such as gasoline, kerosene or paint thinner for cleaning purposes. These solvents will swell rubber components and quickly deteriorate them.

  1. Allow the parts to air dry or use compressed air. Do not use rags for cleaning, since lint will remain in the cylinder bore.
  2.  
  3. Inspect the piston and replace it if it shows scratches.
  4.  



Click image to see an enlarged view

Fig. Fig. 9: Once cleaned and inspected, the wheel cylinder is ready for assembly

  1. Lubricate the cylinder bore and seals using clean brake fluid.
  2.  
  3. Position the spring assembly.
  4.  
  5. Install the inner seals, then the pistons.
  6.  



Click image to see an enlarged view

Fig. Fig. 10: Lubricate the cup seals with brake fluid



Click image to see an enlarged view

Fig. Fig. 11: Install the spring, then the cup seals in the bore



Click image to see an enlarged view

Fig. Fig. 12: Lightly lubricate the pistons, then install them

  1. Insert the new boots into the counterbores by hand. Do not lubricate the boots.
  2.  



Click image to see an enlarged view

Fig. Fig. 13: The boots can now be installed over the wheel cylinder ends

  1. Install the wheel cylinder.
  2.  

 
label.common.footer.alt.autozoneLogo