Hyundai Ioniq: Brake System / Rear Disc Brake. Repair procedures

Hyundai Ioniq (AE) 2017-2024 Service Manual / Brake System / Brake System / Rear Disc Brake. Repair procedures

Removal
[EPB None Apply]
1.
Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2.
Remove the rear wheel and tire (A) from the rear hub.
Tightening torque :
107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb-ft)

   
•
Be careful not to damage the hub bolts when removing the rear wheel and tire (A).
3.
Remove the parking brake cable fixed clip (A).

4.
Pull the operating lever as a direction of arrow in the illustration below and then remove the parking brake cable.

5.
Loosen the guide rod bolt and then pivot the caliper body 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)

6.
Remove the pad return spring (A).

   
•
Pad return springs must be replaced with new ones whenever pads are replaced.
•
Technicians should be careful not to deform pad return springs.
•
When pad return springs are deformed, it may cause improper braking, more fuel consumption.
7.
Separate the brake pad and pad retainer.

8.
Loosen the caliper mounting bolts and then removethe rear caliper assembly (A).
Tightening torque :
63.7 - 73.5 N.m (6.5 - 7.5 kgf.m, 47.0 - 54.2 lb-ft)

9.
Remove the rear brake disc by loosening the screws.
Tightening torque :
4.9 - 5.9 N.m (0.5 - 0.6 kgf.m, 3.6 - 4.3 lb-ft)

[EPB Apply]
1.
Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2.
Remove the rear wheel and tire (A) from the rear hub.
Tightening torque :
107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb-ft)

   
•
Be careful not to damage the hub bolts when removing the rear wheel and tire (A).
3.
Disconnect the EPB connector.

4.
Loosen the guide rod bolt and then remove the caliper body.
Tightening torque :
21.6 - 31.4 N.m (2.2 - 3.2 kgf.m, 15.9 - 23.1 lb-ft)

5.
Remove the pad return spring (A).

   
•
Pad return springs must be replaced with new ones whenever pads are replaced.
•
Technicians should be careful not to deform pad return springs.
•
When pad return springs are deformed, it may cause improper braking, more fuel consumption.
6.
Remove the brake pad.

7.
Remove the pad retainer (A).

   
•
Pad retainer must be replaced with new ones whenever pads are replaced.
8.
Loosen the caliper mounting bolts and then removethe rear caliper assembly (A).
Tightening torque :
78.5 - 98.1 N.m (8.0 - 10.0 kgf.m, 57.9 - 72.3 lb-ft)

9.
Remove the rear brake disc by loosening the screws.
Tightening torque :
4.9 - 5.9 N.m (0.5 - 0.6 kgf.m, 3.6 - 4.3 lb-ft)

Replacement
Brake Pad
[EPB None Apply]
1.
Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2.
Remove the rear wheel and tire (A) from the rear hub.

   
•
Be careful not to damage the hub bolts when removing the rear wheel and tire (A).
3.
Remove the parking brake cable fixed clip (A).

4.
Pull the operating lever as a direction of arrow in the illustration below and then remove the parking brake cable.

5.
Loosen the guide rod bolt and then pivot the caliper body up out of the way.

6.
Remove the pad return spring (A).

7.
Replace the brake pad and pad retainer.

8.
Install the pad return spring (A).

   
•
Pad return springs must be replaced with new ones whenever pads are replaced.
•
Technicians should be careful not to deform pad return springs.
•
When pad return springs are deformed, it may cause improper braking, more fuel consumption.
9.
Use a SST (09580-0U000) when installing the brake caliper assembly.

10.
Install the caliper body (A) then tighten the guide rod bolt (B).
Tightening torque :
21.6 - 31.4 N.m (2.2 - 3.2 kgf.m, 15.9 - 23.1 lb-ft)

11.
Pull the operating lever as a direction of arrow in the illustration below and then install the parking brake cable.

12.
Install the parking brake cable fixed clip (A).

13.
Install the rear wheel and tire (A) from the rear hub.
Tightening torque :
107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb-ft)

   
•
Be careful not to damage the hub bolts when Installing the rear wheel and tire (A).
[EPB Apply]
1.
Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2.
Remove the rear wheel and tire (A) from the rear hub.

   
•
Be careful not to damage the hub bolts when removing the rear wheel and tire (A).
3.
Disconnect the EPB connector.

4.
Loosen the guide rod bolt and then remove the caliper body.

5.
Remove the pad return spring (A).

6.
Remove the brake pad.

7.
Remove the pad retainer (A).

   
•
Return spring (A), Pad retainer (B), inner shim (C) and pad (D) must be replaced with new ones whenever pads are replaced.

8.
Install the pad return spring (A).

   
•
Pad return springs must be replaced with new ones whenever pads are replaced.
•
Technicians should be careful not to deform pad return springs.
•
When pad return springs are deformed, it may cause improper braking, more fuel consumption.
9.
Install the caliper body (A) then tighten the guide rod bolt (B).
Tightening torque :
21.6 - 31.4 N.m (2.2 - 3.2 kgf.m, 15.9 - 23.1 lb-ft)

   
•
Rotate the caliper piston and push the direction of the arrow.

10.
Connect the EPB connector.

11.
Install the rear wheel and tire (A) from the rear hub.
Tightening torque :
107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb-ft)

Inspection
Rear 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 24 points, at least, of same distance (5mm) from the brake disc outer circle.
Brake disc thickness
Standard : 10 mm (0.394 in)
Service limit : 8.4 mm (0.331 in)
Deviation : less than 0.015 mm (0.0002 in)

4.
If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle.
Rear 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 : 15 mm (0.60 in)
Service limit : 7.0 mm (0.28 in)
2.
Check the damage of pad, backing metal and contamination with grease.
Rear Brake Disc Runout Check
1.
Place a dial gauge about 10mm (0.2 in.) from the outer circumference of the brake disc, and measure the runout of the disc.
Brake disc runout
Limit : 0.055 mm (0.0016 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 exceeds 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.
To install, reverse the removal procedure.
2.
Use a SST (09580-0U000) when installing the brake caliper assembly.

   
•
Wind the piston into the caliper body until it is fully retracted.
•
Do not use any power assisted tools for this task.
3.
After installing, bleed the brake system.
(Refer to Brake System - "Brake System Bleeding")
Adjustment
Parking Brake
   
•
Re-setting of the parking brake is necessary after overhauling the caliper body, or if the brake calipers, housing, parking brake cable or brake discs have been changed.
1.
Remove the floor console to reach the adjusting nut.
2.
Loosen the parking brake cable until both operating levers rest in fully off position.
3.
Bring the brake pads in their operating position by pressing the brake pedal down several times until there is resistance.
4.
Tension the parking brake cable by tightening the adjusting nut, until the operating levers on both calipers lift from the stop, up to a distance of (A) and (D) between operating lever (B) and stopper (C).
Distance (A+D) : Max. 3 mm (0.12 in)

5.
Refit the floor console.
6.
Parking brake lever in the car must be in fully loosened position.
7.
If the handbrake cables where changed, actuate the parking brake a few times with maximum force to stretch the parking brake cables, and then control adjusting as above.
8.
Check the wheels of their free operation.
9.
Test drive.

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