Disc & Drum: Removal & Installation Kia Spectra I

Removal (Sephia & Spectra)

1. Raise and support vehicle. Remove front wheels. Remove plastic caps. Remove 2 bolts and bushings. Remove caliper and wire aside. Remove spring clip. Remove brake pads. (Scheme 1) Measure brake pad thickness. Replace pad if lining thickness is less than.08" (2.0 mm).
2. Prepare to catch any brake fluid. Using flare nut wrench, disconnect brake hose. Remove 2 bolts and supporting plate. Remove caliper. Measure runout at outer braking contact edge of rotor. Maximum runout should be.004" (.10 mm).

Scheme 1

Installation (Sephia & Spectra)

To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM . Inspect brake system for leaks.

Removal & Installation (Sportage)

Raise and support vehicle. Remove 2 caliper assembly bolts, and pull caliper from disc. Remove flexible hose mounting bolt, and disconnect flexible hose from caliper. Remove brake pads from adapter. Remove 2 adapter mounting bolts, and then remove adapter. Remove 2 screws. Remove caliper. To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM . 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. Using a dial indicator, measure brake rotor runout. Compare to specifications and resurface or replace as necessary. See DISC BRAKE SPECIFICATIONS . To install, reverse removal procedure.

Raise and support vehicle. Remove parking cable and clip. Remove brake hose connecting bolt from caliper. Clamp rear brake hose. Remove 2 lock bolts from caliper. Remove caliper from rotor. Remove 2 "V" springs from disc pads. (Scheme 2) Remove disc pads, shims and guide plates. Remove 2 bolts from mounting support. Remove mounting support from rear wheel spindle. Measure pad thickness. Replace pad if lining thickness is less than.079" (2.01 mm). To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS. Bleed brake system. See BLEEDING BRAKE SYSTEM. Inspect brake system for leaks.

Scheme 2

Remove rear brake pads and caliper. See REAR DISC BRAKE PADS & CALIPER (SEPHIA & SPECTRA) . Using a dial indicator check disc runout. Resurface or replace if runout exceeds .004" (.10 mm). Remove rotor mounting screws. Using dial indicator check disc rotor thickness. Resurface or replace rotor if beyond minimum thickness. See DISC BRAKE SPECIFICATIONS .

1. Raise and support vehicle. Remove rear wheels, and release parking brake. Using impact driver, remove 2 mounting screws and brake drum.
2. Remove top return spring. Remove front and rear shoe spring clip and hold pins. Remove anti-rattle spring and adjuster spring. Note position of operating lever while holding front shoe. Remove bottom return spring.
3. Disconnect parking brake cable from rear shoe by removing clip and washer. Remove front and rear brake shoes. Remove attaching bolt, and remove wheel cylinder, if required.

To install, reverse removal procedure. Coat all internal parts of wheel cylinders with clean brake fluid. Apply brake grease to wheel cylinder and anchor sliding points, adjuster threads and shoe contact points on backing plate. Adjust brake shoes. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM . Inspect brake system for leaks.

Removal (Sportage)

1. Loosen lug nuts. Raise and support vehicle. Remove front wheel. Set parking brake. Loosen and remove 4 hub nuts and screws. Release parking brake, and remove wheel drum.
2. Using spring wrench or pliers, remove adjuster lever spring. Remove adjuster lever. Using spring wrench or pliers, remove return spring. Turn adjuster star wheel clockwise to relieve tension on shoes. Remove adjuster assembly.
3. Turn holding pins until they align with holding spring clip groove. Remove holding pins and spring clips. Remove primary shoe and anchor spring. Remove secondary brake shoe with parking cable attached. Remove brake cable from shoe. Remove control lever "C" clip and lever from secondary brake shoe.
4. Disconnect brakeline from wheel cylinder. Remove 2 wheel cylinder mounting bolts, and remove wheel cylinder. Remove parking brake cable from backing plate. Remove 4 nuts from backing plate. Tap axle from behind with rubber hammer. Remove axle from housing. Remove backing plate.

Installation

1. Install wheel cylinder, and tighten 2 mounting bolts to specification. See «TORQUE SPECIFICATIONS»(ref-4719-S29587004862000072000000) . Apply grease to wheel cylinder contact points. Install brakeline to wheel cylinder.
2. Install control lever on secondary shoe with NEW "C" clip. Using pliers, connect parking brake cable to secondary shoe. Attach secondary shoe to backing plate with holding pin and spring clip. Attach one end of anchor spring to secondary shoe, and the other end to primary shoe. Position primary shoe, and install holding pin and spring clip.
3. Install adjusting assembly. Using spring wrench, install return spring. Install adjusting lever and adjusting lever spring. Ensure adjusting lever contacts star wheel on adjuster assembly.
4. Measure outer shoe diameter when installed on drums. Measure drum inner diameter. Calculate clearance by subtracting shoe diameter from drum diameter. Clearance should be .020-.040" (.51-1.02 mm).
5. Install drum and set parking brake. Install and tighten 3 hub bolts. Release parking brake, and install tire. Loosely tighten lug nuts. Lower vehicle. Tighten all bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-4719-S29587004862000072000000) . Add brake fluid, and bleed brakes. See «BLEEDING BRAKE SYSTEM»(ref-4719-S13378919292000072000000) . Check for fluid leakage.

Disconnect battery ground cable. Disconnect fluid level switch connector. Disconnect and plug brake lines at master cylinder to prevent entry of dirt and loss of fluid. Remove 2 master cylinder nuts. Remove master cylinder.

To install master cylinder, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM .

1. Disconnect clutch fluid hose from back of master cylinder reservoir, and drain reservoir. Remove connector to fluid level and differential sensor. Using line wrench, remove brakelines from master cylinder to proportioning valve.
2. Using line wrench, remove rear wheel brake line from right side of ABS solenoids Remove front wheel brakeline from lower left port of proportioning valve. Remove wire harness connector to ABS solenoids. Remove wire harness connector to proportioning valve.
3. Remove nuts attaching master cylinder to power brake booster. Remove bracket holding ABS solenoids and proportioning valves. Remove master cylinder from power brake booster.

Installation (Sportage)

1. Position NEW gasket on master cylinder, and adjust push rod length. Attach proportioning valve and ABS solenoids to bracket. Place master cylinder on power brake booster unit studs. Place bracket assembly on power brake booster studs, and install nuts.
2. Attach rear wheel brakeline to right side port of ABS solenoid. Attach front wheel brakeline to lower left port of proportioning valve. Attach brakelines to master cylinder.
3. Connect fluid level and differential sensor connector. Connect ABS solenoid and proportioning valve wire harness connectors. Fill reservoir tank to MAX level. Check for fluid leakage. If needed, adjust brake pedal free play and height. See «BRAKE PEDAL FREE PLAY»(ref-4719-S07189071672000072000000) and «BRAKE PEDAL HEIGHT & BRAKELIGHT SWITCH»(ref-4719-S08165012492000072000000) under ADJUSTMENTS. Bleed brake system. See «BLEEDING BRAKE SYSTEM»(ref-4719-S13378919292000072000000) . Tighten nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-4719-S29587004862000072000000) .

Remove master cylinder and bracket assembly. See MASTER CYLINDER . Disconnect vacuum hose at power brake booster. From inside vehicle, remove cotter pin and clevis pin from brake pedal. From inside vehicle, remove lock nuts. Remove "U" type link. Remove power brake booster.

1. Insert brake booster, and connect "U" type link. Attach and tighten lock nuts. Pull brake pedal down to "U" type link. Insert clevis pin, and fix with NEW cotter pin.
2. Place gasket onto master cylinder. Position push rod adjuster onto gasket, and tighten adjusting bolt until bolt touches bottom of push rod hole. Apply 500 mm Hg vacuum with vacuum pump. Place Master Cylinder Gauge (K95U-5200-B) onto power brake booster unit with tip of adjusting bolt touching push rod.
3. Check clearance between edge of adjusting bolt and power brake unit push rod. Clearance should be .004-.012" (.10-.30 mm). If clearance is not within specification, loosen push rod lock nut, and turn push rod. Install master cylinder and bracket assembly. See «MASTER CYLINDER»(ref-4719-S28462103042000072000000) . Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-4719-S29587004862000072000000) .

1. Remove master cylinder. See «MASTER CYLINDER»(ref-4719-S28462103042000072000000) . Disconnect vacuum hose from booster. From inside vehicle, remove spring clip from clevis pin.
2. Remove 4 booster nuts. Remove booster. Remove mounting bracket gasket.

1. Mount booster to vehicle bulkhead with NEW gasket. Install 4 mounting nuts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-4719-S29587004862000072000000) .
2. Attach push rod clevis pin to brake pedal with NEW clevis pin and NEW spring clip. From engine compartment, attach vacuum hose to check valve. Mount master cylinder onto power brake unit, and install 2 nuts. Tighten master cylinder mounting nuts to specification. See «TORQUE SPECIFICATIONS»(ref-4719-S29587004862000072000000) .
3. Connect 4 brakelines. Tighten brakeline flare nuts to specification. See «TORQUE SPECIFICATIONS»(ref-4719-S29587004862000072000000) . Connect brake fluid level switch. Fill reservoir with NEW fluid to MAX level line.
4. Bleed system. See «BLEEDING BRAKE SYSTEM»(ref-4719-S13378919292000072000000) . Inspect system for leaks. Check brake pedal height and free play. Adjust as necessary. See «BRAKE PEDAL FREE PLAY»(ref-4719-S07189071672000072000000) and «BRAKE PEDAL HEIGHT & BRAKELIGHT SWITCH»(ref-4719-S08165012492000072000000) under ADJUSTMENTS.