Kia Forte: Brake System / Rear Disc Brake

Kia Forte 2019-2021 (BD) Service Manual / Brake System / Brake System / Rear Disc Brake

Components and components location
Components

1. Lever spring
2. Cable guide
3. Lever
4. Caliper body
5. Caliper carrier
6. Pad liner
7. Brake pad [In]
8. Brake pad [Out]
9. Return spring
10. Bleed screw cap
11. Bleed screw

Repair procedures
Removal
1.

Remove the rear wheel and tire (A).

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 to the hub bolts when removing the rear wheel and tire.

2.

Release the parking brake lever and parking brake cable is loose.

3.

Remove the parking brake cable (B), after removing the clip (A).

[Couple torsion beam axle type]

[Multi link type]

4.

Disconnect the brake hose (A) from the brake caliper by loosening the bolt.

Tightening torque :

24.5 - 29.4 N·m (2.5 - 3.0 kgf·m, 18.1 - 21.7 lb·ft)

5.

Loosen the guide rod bolt (A) and then remove the caliper body (B).

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 springs (A).

7.

Remove the brake pads (A).

8.

Remove the pad liner (A).

  

Place the return spring, pad liner, inner brake shim, and brake pad all at the same time when replacing the brake pad.

9.

Remove the brake caliper (A) by loosening the bolts.

[Couple torsion beam axle type]

Tightening torque :

63.5 - 73.5 N·m (6.5 - 7.5 kgf·m, 47.0 - 54.2 lb·ft)

[Multi link type]

Tightening torque:

78.4 - 98.0 N·m (8.0 - 10.0 kgf·m, 57.8 - 72.3 lb·ft)

10.

Remove the rear brake disc (A) by loosening the screws.

Tightening torque:

4.9 - 5.9 N·m (0.5 - 0.6 kgf·m, 3.6 - 4.3 lb·ft, 43.4 - 52.1 lb·in)

Replacement
1.

Remove the rear wheel and tire (A).

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 to the hub bolts when removing the rear wheel and tire.

2.

Release the parking brake lever and parking brake cable is loose.

3.

Remove the parking brake cable (B), after removing the clip (A).

[Couple torsion beam axle type]

[Multi link type]

4.

Loosen the guide rod bolts (A) and then hold the caliper body (B) with wire.

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 springs (A).

6.

Remove the brake pads (A).

7.

Remove the pad liner (A).

  

Place the return spring, pad liner, inner brake shim, and brake pad all at the same time when replacing the brake pad.

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 8 points, at least, at the same distance apart (5mm) from the brake disc outer circle.

Rear Brake disc thickness

Standard: 10 mm (0.3937 in)

Service limit: 8.4 mm (0.3307 in)

Deviation: less than 0.005 mm (0.0002 in)

4.

If wear exceeds the limit, swab left and right discs and pad assemblies 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: 9.0 mm (0.3543 in)

Service limit: 2 mm (0.0787 in)

2.

Check that grease is applied to sliding contact points and check the pad and backing metal for damage.

Rear 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: 0.03 mm (0.00118 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 brake disc again for runout.

4.

If the runout cannot be corrected by changing the position of the brake disc, replace the brake disc.

Installation
1.

Install in the reverse order of removal.

2.

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

3.

After installation, bleed the brake system.

(Refer to Brake system - "Brake Bleeding Prcoedures")

  

Bring the brake pads in their operating position by pressing the brake pedal down (half of normal pedal travel) several times until there is resistance.

In order to bed the brake pads to the brake disc and ensure performance and endurance, the vehicle user must be instructed to avoid heavy braking or sustained periods with the brakes applied, for the first 200km(124mile) after installing new pads.

Re-setting of the parking brake is necessary after overhauling the caliper body, or if the brake calipers, caliper body, parking brake cable or brake discs have been changed.

Front Disc Brake
Components and components location Components 1. Caliper body 2. Caliper carrier 3. Brake pad [In] 4. Brake pad [Out] 5. Return spring 6. Pad liner ...

Rear Drum Brake
Components and components location Components 1. Shoe hold down pin 2. Shoe adjuster 3. Upper return spring 4. Adjusting lever 5. Shoe 6. Adjusting s ...

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