| SONATA(YF) >2012 > G 2.4 GDI > Brake System > Brake System > Front Disc Brake>Repair procedures |

Removal

1. | Remove the front wheel & tire.

Tightening torque:
88.3 ~107.9 N.m (9.0 ~11.0 kgf.m, 65.1 ~79.6 lb-ft)

2. | Loosen the hose eyebolt (B) and caliper mounting bolts (C), then remove the front caliper assembly (A).

Tightening torque:
Brake hose to caliper(B):
24.5 ~29.4 N.m (2.5 ~3.0 kgf.m, 18.1 ~21.7 lb-ft)
Caliper assembly to knuckle(C):
78.5 ~98.1 N.m (8.0 ~10.0 kgf.m, 57.9 ~72.3 lb-ft)

Do not loosen the bolts(E) instead of guide rod bolt.

3. | Remove the front brake disc by loosening the screws (A).

Replacement

Front brake pads

1. | Remove the brake hose mounting bracket bolt (A).

2. | Loosen the guide rod bolt (B) and pivot the caliper (A) up out of the way.

Tightening torque:
21.6 ~31.4 N.m (2.2 ~3.2 kgf.m, 15.9 ~23.1 lb-ft)

3. | Replace pad shim (D), pad retainers (C) and brake pads (B) in the caliper bracket (A).

Inspection

Front brake disc thickness check

1. | Check the brake pads for wear and fade.

2. | Check the brake disc for damage and cracks.

3. | Remove all rust and contamination from the surface, and measure the disc thickness at 8 points, at least, of same distance (5mm) from the brake disc outer circle.

Front brake disc thickness
- Standard : 28 mm (1.10 in)
- Service Limit : 26.4 mm (1.04 in)
Deviation: Less than 0.005mm (0.0002in)

4. | If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle.

Front Brake Pad Check

1. | Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value.

Pad thickness
Standard value: 11 mm (0.43 in)
Service limit: 2.0 mm (0.0787 in)

2. | Check that grease is applied, to sliding contact points and the pad and backing metal for damage.

Front brake disc runout check

1. | Place a dial gauge about 5mm (0.2 in.) from the outer circumference of the brake disc, and measure the runout of the disc.

Brake disc runout
Limit: 0.025 mm (0.00098 in.) or less (new one)

2. | If the runout of the brake disc exceeds the limit specification, replace the disc, and then measure the runout again.

3. | If the runout does not exceed the limit specification, install the brake disc after turning it 180° and then check the runout of the brake disc again.

4. | If the runout cannot be corrected by changing the position of the brake disc, replace the brake disc.

Installation

1. | Installation is the reverse of removal.

2. | Use a SST (09581-11000) when installing the brake caliper assembly.

3. | After installation, bleed the brake system. (Refer to Brake system bleeding)

• | Do not hit piston end by hammer or prying directly against piston face with screwdriver to push in piston.

• | Using wood or used pad to protect piston end and pushing the wood or pad is recommended.

• | When spreading a piston, SST should be cover all area of piston end face.