Complete rebuild of rear brake calipers including disassembly, cleaning, replacement of seals and dust boots, lubrication, and reassembly to restore proper braking function.

Warnings

Tools required

Parts

• Rear brake caliper rebuild kit (includes pistons, seals, dust boots, and hardware) × 2 — Use OEM Hyundai specification
• Silicone brake grease (high-temperature) × 1 — Use brake-specific silicone lubricant
• Brake cleaner spray × 1 — Non-chlorinated preferred

Fluids

• DOT 4 Brake Fluid — 1 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock front wheels securely
3. Remove approximately half of brake fluid from master cylinder reservoir using turkey baster to prevent overflow during piston compression
4. Loosen rear wheel lug nuts while vehicle is on ground
5. Lift rear of vehicle and support securely on jack stands rated for vehicle weight
6. Remove rear wheels completely
7. Verify you have complete caliper rebuild kits for both rear calipers before beginning disassembly
8. Inspect brake rotors for wear or damage; resurface or replace if necessary before rebuilding calipers

Procedure

1. 1

   Remove brake caliper assembly
   Remove caliper slide pin bolts using appropriate socket. Carefully lift caliper off rotor and suspend using wire or bungee cord to avoid stressing brake hose. Do NOT let caliper hang by brake hose. Mark caliper orientation for reassembly reference.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
2. 2

   Disconnect brake hose from caliper
   Place drain pan under caliper. Using flare nut wrench, carefully disconnect brake hose from caliper body. Immediately plug or cap brake hose end to minimize fluid loss and prevent contamination. Allow caliper to drain completely into pan. Move caliper to clean workbench area.
3. 3

   Disassemble caliper and remove piston
   Remove dust boot retaining ring if present. Carefully pry out dust boot using pick tool. Place caliper body on wooden blocks with piston facing up. Use compressed air applied to brake fluid inlet port to gently push piston out of bore. Use LOW pressure and control piston with hand to prevent it from shooting out. Never place fingers directly in front of piston during air pressure application.
4. 4

   Remove internal seals
   Using plastic pick or seal removal tool, carefully extract piston seal from groove inside caliper bore. Take care not to scratch or gouge the bore surface. Remove all old seal material completely. Inspect piston seal groove for corrosion or damage.
5. 5

   Clean and inspect caliper components
   Thoroughly clean caliper bore, piston, and all internal passages using brake parts cleaner and non-metallic wire brush. Blow dry with compressed air. Inspect caliper bore for scoring, corrosion, or pitting. Inspect piston chrome plating for damage, corrosion, or peeling. Any significant damage requires caliper replacement, not rebuild. Clean slide pin bores thoroughly.
6. 6

   Install new piston seal
   Lubricate new piston seal lightly with clean DOT 4 brake fluid (never silicone grease). Carefully install seal into caliper bore groove using fingers only, ensuring seal seats completely and evenly around entire circumference. Verify seal is not twisted or pinched.
7. 7

   Install new piston
   Lubricate new or cleaned piston outer surface with clean DOT 4 brake fluid. Lubricate caliper bore lightly with brake fluid. Carefully insert piston into bore, ensuring piston enters squarely and does not cock or bind. Push piston in by hand until it bottoms in bore. Do not use excessive force.
8. 8

   Install new dust boot
   Install new dust boot onto piston according to rebuild kit instructions. Ensure boot lip seats properly in caliper body groove and on piston groove. Install dust boot retaining ring if equipped, ensuring it snaps completely into place. Verify boot is not twisted or torn.
9. 9

   Service caliper slide pins
   Remove slide pins from caliper bracket. Clean pins thoroughly with brake cleaner and inspect for corrosion or wear. Clean slide pin bores in bracket. Apply thin coat of high-temperature silicone brake grease to slide pins (included in most rebuild kits). Reinstall pins into bracket, ensuring smooth movement.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
10. 10

    Reconnect brake hose to caliper
    Remove plug from brake hose. Install new copper crush washers on both sides of banjo fitting if applicable (included in rebuild kit). Thread brake hose onto caliper body or install banjo bolt, tightening to finger tight initially. Final torque will be applied after installation on vehicle. Ensure hose routing is correct and will not interfere with suspension or wheel.
11. 11

    Reinstall caliper assembly
    Apply thin coat of silicone brake grease to slide pin contact points. Position caliper over brake pads and rotor, aligning with slide pins. Install and torque caliper slide pin bolts to specification. Verify caliper moves freely on slide pins and pads contact rotor evenly.
    Torque spec

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)
12. 12

    Bleed brake caliper
    Attach clear plastic tubing to bleeder screw and place other end in catch container with small amount of clean brake fluid. Have assistant slowly pump brake pedal 3-4 times and hold pressure. Open bleeder screw approximately 1/2 turn. Allow fluid and air to flow into container until stream is solid (no bubbles), then close bleeder screw before pedal reaches floor. Repeat until no air bubbles appear in fluid. Torque bleeder screw to specification. Do not overtighten.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
13. 13

    Repeat for opposite side
    Perform steps 1 through 12 on the opposite rear caliper. Both rear calipers should be rebuilt together to ensure balanced braking performance. Maintain cleanliness throughout the process.
14. 14

    Reinstall wheels and final checks
    Reinstall rear wheels and hand-tighten lug nuts in star pattern. Lower vehicle to ground. Torque wheel lug nuts to specification in star pattern. Refill master cylinder reservoir to MAX line with fresh DOT 4 brake fluid. Pump brake pedal firmly multiple times until pedal becomes firm.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Ensure all caliper slide pins move freely and are properly lubricated with silicone brake grease, not standard grease
2. Verify brake hose connections are tight and properly oriented without twisting or kinking
3. Confirm bleeder screws are closed and torqued to specification before test driving
4. All torque specifications must be achieved using calibrated torque wrench, particularly caliper slide pin bolts which are critical for safe operation

Verification

• With engine off, pump brake pedal multiple times. Pedal should become firm and hold pressure without sinking
• Start engine and verify brake pedal does not sink when held under constant pressure for 30 seconds
• Check for brake fluid leaks at all caliper connections, bleeder screws, and brake hose fittings
• Perform low-speed test drive in safe area, testing brake response and ensuring no pulling to either side
• Verify parking brake operates correctly and holds vehicle on incline
• After test drive, recheck brake fluid level and top off if necessary. Check all connections for leaks
• Perform 10-15 moderate brake applications from 30 mph to bed in rebuilt calipers before normal driving
• If brake pedal feels soft, spongy, or travels too far, re-bleed brake system completely before further operation

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