Disc & Drum: Removal & Installation Kia Optima I

Removal

Note. Hydraulic portion of brake caliper assembly may be referred to as the brake cylinder.

1. Raise and support vehicle. Remove wheel and tire assembly.
2. Check pad lining thickness through cylinder inspection hole. If pad lining thickness is out of specification, replace pads. See «DISC PAD LINING THICKNESS»(ref-179107-S38656029692005063000000) table. DISC PAD LINING THICKNESS Application In. (mm) Pad Lining Thickness Standard.433 (11.00) Service Limit.079 (2.0)
3. Remove 2 bolts from torque plate (carrier) and remove brake cylinder. Suspend cylinder with wire. NOTE: DO NOT disconnect brake hose.
4. Remove pads. (Scheme 1)
5. If caliper assembly is to be removed from vehicle, remove brake hose from caliper assembly and plug all openings. Remove caliper assembly by removing torque plate (carrier).

Scheme 1

Installation

1. Install pad clips. Install pads onto each clip. Position pad with its pad wear sensor to piston side. Remove dust before positioning pad clip or replace with a new one if clip is damaged.
2. Press piston inward with a hammer handle or similar tool. Lower and insert brake cylinder carefully so as not to damage boot. Install 2 guide rod bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-179107-S36341252762005063000000) . Install brake hose to caliper. Fill brake reservoir with DOT 3 brake fluid. Bleed brake system. See «BLEEDING BRAKE SYSTEM»(ref-179107-S25975970632005063000000) . Inspect brake system for leaks.

Removal & Installation

Raise and support vehicle. Remove front wheels. Remove brake caliper. See FRONT DISC BRAKE PADS & CALIPER . Using a micrometer, measure brake rotor thickness in 8 places. Using a dial indicator, measure brake rotor runout. Compare to specifications and resurface or replace rotor as necessary. See DISC BRAKE SPECIFICATIONS . To install, reverse removal procedure.

1. Detach brakelines from master cylinder and install plugs to prevent contamination.
2. Remove master cylinder mounting nuts and lift out master cylinder.

1. Inspect length of output rod and adjust length to 0.32-0.33" (8.125-8.375 mm).
2. Install master cylinder on brake booster. Tighten mounting nuts to specification. See «TORQUE SPECIFICATIONS»(ref-179107-S36341252762005063000000) . Connect brakelines to master cylinder.
3. Fill brake reservoir with DOT 3 brake fluid and bleed system. See «BLEEDING BRAKE SYSTEM»(ref-179107-S25975970632005063000000) .

1. Remove the main floor console. Detach parking brake switch connector. Disconnect parking brake lever from parking brake cable. Remove parking brake lever. see scheme 5
2. Remove rear seat cushion and take up the carpet as necessary. Remove parking brake cable clamp and grommet. Note grommet direction for installation reference. Move the center muffler heat protector center panel toward the front. Remove washer assembled bolt and detach the clamp bracket.
3. Remove wheel and tire assembly. Remove brake drum or rotor. Remove the rear hub assembly. Remove the springs and shoe hold down pins. Remove cable clip. Disconnect the cable end from the trailing shoe. Drive out the parking brake cable to the under body side.

1. To ensure correct installation, check the parking brake cables for an identification paint mark or wind tape located near mid-point of cable housing. See «PARKING BRAKE CABLE IDENTIFICATION»(ref-179107-S33602162992005063000000) table. PARKING BRAKE CABLE IDENTIFICATION Application Cable Color Code Drum Brake Right Side Yellow Left Side Red Disc Brake Right Side White Left Side None
2. Install cables to underside of body and secure with mounting screws. To aid in connecting components, place cable ends near adjuster lever and rear brake backing plates. Connect cable to brake shoe.
3. Set the adjuster lever all the way back when installing the shoe-to-shoe spring. Install the grommet in correct direction as noted in removal procedure. Apply a coating of Multipurpose Grease (SAE J310, NLGI No. 2) to each sliding part of the ratchet plate or the ratchet pawl. Attach cables to parking brake lever.
4. After all components are installed, adjust the parking brake lever stroke. See «PARKING BRAKE»(ref-179107-S31985697022005063000000) under ADJUSTMENTS.

1. Using appropriate container, prepare to catch brake fluid. Carefully remove brakeline from proportioning valves located on bottom of master cylinder. After any residual pressure is released, remove proportioning valve from master cylinder. Plug all fluid openings.
2. To install, reverse removal procedure. Tighten proportioning valve mounting nut to specification. See «TORQUE SPECIFICATIONS»(ref-179107-S36341252762005063000000) . Fill hydraulic system with DOT 3 brake fluid. Bleed brake system. See «BLEEDING BRAKE SYSTEM»(ref-179107-S25975970632005063000000) .

Note. Power brake booster is not serviceable. DO NOT attempt to disassemble the brake booster.

1. Remove master cylinder. See «MASTER CYLINDER»(ref-179107-S21568053342005063000000) . Remove vacuum hose. Remove operating rod from brake pedal.
2. Loosen booster mounting nuts. Remove power brake booster assembly.

1. Install master cylinder. Attach booster/master cylinder to dash panel. Reinstall vacuum hose securely to prevent vacuum leaks. Couple operating rod with brake pedal.
2. Bleed system. See «BLEEDING BRAKE SYSTEM»(ref-179107-S25975970632005063000000) . Inspect system for leaks. Check brake pedal height and free play. Adjust as necessary. See «BRAKE PEDAL FREE PLAY»(ref-179107-S09433088722005063000000) under ADJUSTMENTS. Also see «BRAKE PEDAL HEIGHT & BRAKELIGHT SWITCH»(ref-179107-S26172482672005063000000) under ADJUSTMENTS.

Note. Hydraulic portion of brake caliper assembly may be referred to as the brake cylinder.

Scheme 2

Scheme 3

Scheme 4

1. Before replacing brake pads, remove brake fluid from master cylinder reservoir until it is half full. Raise and support vehicle. Remove wheel and tire assembly.
2. Check pad lining thickness through cylinder inspection hole. If pad lining thickness is out of specification, replace pads. See «DISC PAD LINING THICKNESS»(ref-179107-S38656029692005063000000) table.
3. Remove caliper mounting bolts and remove caliper assembly. Remove carrier bolt and remove carrier with brake pad.
4. Remove piston boot and piston from cylinder assembly. Remove piston seal with fingers. (Scheme 3) CAUTION: DO NOT use sharp tools to remove brake cylinder components.
5. Check for worn, damaged or rusted piston bore and piston. Replace damaged parts if necessary. Check for damaged piston seal, boot, and pin insulators.
6. Apply DOT 3 brake fluid to piston seal, cylinder inner side, piston boot and piston outer surface. Install appropriate lubricant to guide rod insulators.
7. Push piston into caliper. Align piston matching mark upward (Scheme 4)
8. To complete installation, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-179107-S36341252762005063000000). Bleed brake system. See «BLEEDING BRAKE SYSTEM»(ref-179107-S25975970632005063000000).

1. Raise and support vehicle. Remove rear wheel and tire assembly. Remove rear brake drums.
2. Remove rear hub. Remove shoe return spring, cylinder end shoe spring, and shoe hold down spring. (Scheme 5)
3. Remove shoes and adjuster as an assembly. Disconnect brakeline from wheel cylinder. Plug brakeline to prevent fluid loss. Remove bolt and wheel cylinder.

Scheme 5

1. Apply appropriate lubricant to each place where metal components contact each other. Ensure lubricant is applied to shoe and backing plate contact surfaces. Also lubricate shoe and anchor plate contact surfaces.
2. To complete installation, reverse removal procedure. Install shoe hold down pin. Assemble return spring with push rod shortened. Check outside dimension of brake shoes. (Scheme 6) Adjust to 8.96-8.98" (227.6-228.1 mm).
3. Install brake drums and rear wheels. Adjust parking brake. See «PARKING BRAKE»(ref-179107-S31985697022005063000000) under ADJUSTMENTS. Bleed brake system. See «BLEEDING BRAKE SYSTEM»(ref-179107-S25975970632005063000000).

Scheme 6