Hyundai Tucson: 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 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).

4.
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)

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.

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: 0.04 mm (0.00157 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)
Front Disc Brake Components and Components Location
Components 1. Guide rod bolt2. Bleed screw3. Caliper bracket 4. Caliper body5. Inner pad shim6. Brake pad7. Pad retainer ...

Rear Disc Brake Components and Components Location
Components 1. Guide rod bolt2. Bleed screw3. Caliper bracket4. Caliper body5. Inner pad shim6. Brake pad7. Pad retainer ...

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