Operation CHARM: Car repair manuals for everyone.
Home >> Hyundai >> 2002 >> Santa Fe GLS V6-2.7L >> Repair and Diagnosis >> Brakes and Traction Control >> Disc Brake System >> Brake Caliper >> Service and Repair >> Rear
Manuals through 2025 now available!

Our trusted friends have launched a new website named LEMON, which has newer manuals. It also contains all the CHARM manuals.

LEMON is the spiritual successor to CHARM, I recommend you try it!

Link: lemon-manuals.la or lemon-manuals.org.ua

(Some people have issue connecting. LEMON is investigating. For now, use Firefox or change your DNS server)

Or, hide this message: temporarily or permanently

Rear

REMOVAL
1. Remove the rear wheel.
2. Remove the caliper assembly.
3. Remove the brake hose from the caliper assembly.

DISASSEMBLY
1. Remove the pad.





2. Remove the piston boot from the housing, and remove the piston.
3. Remove the piston by applying compressed air through the brake hose fitting.





CAUTION: Do not place your fingers in front of the piston when using compressed air.





4. Using a screwdriver, remove the piston seal carefully so as not to damage the cylinder wall.





5. Clean all removed parts with the specified fluid.

CAUTION: Rubber parts should be replaced with new ones but if you want to reuse them, don't put them in alcohol for more than thirty minutes.

INSPECTION
1. Check the piston and its inside for wear, damage and rust.
Replace the damaged parts if necessary





2. Check the piston seal, boot, and pin insulators for wear and damage.

REASSEMBLY
1. When disassembling the caliper assembly, use a new piston seal and boot.





2. Apply the recommended fluid to the bearing part of the piston seal and piston. Insert the piston seal into grooves inside the caliper, being careful not to twist the seal.





3. Install the piston boot to the piston. Confirm that the concave part of the piston is situated outward and the boot fits in grooves of the piston well.





4. Install the piston and boot in the caliper housing. Insert the boot flange in the caliper housing and check that the boot fits in grooves around the piston.
5. Apply the recommended oil to the inside of the locating pin insulator.

INSTALLATION




1. Install.

2. Perform a road test.

NOTE: If there is a small quantity of air in the brake line, it can affect the brake pedal stroke so you must bleed the system carefully.

CAUTION: When replacing the piston seal, check the pedal stroke. If the pedal stroke is too great, the piston may not retain the piston seal.
Adjust as follows :
1. After removing the pad from the piston, push the piston into the cylinder 3 - 5 mm. Put a lever or steel plate between the piston and disc, being careful not to damage the contact surface of the disc or the piston end.
2. Install the pad. Restore the brake pedal to the original position and step on it 2 - 3 times.
3. Repeat the above procedure more than 5 times and move the piston outward and inward to assure that the piston seat is properly installed.
4. Before driving a vehicle, step on the brake pedal and release it many times.
5. Perform the road test.
pro multis · About Operation CHARM