This procedure covers the removal and replacement of the brake caliper bracket on a 2015 Kia Forte 1.8L, including proper torque specifications and brake system bleeding.

Warnings

Tools required

Parts

• Brake caliper bracket (front) × 1 — Use OEM specification or quality aftermarket
• Copper brake hose washers × 2 — 18mm copper crush washers
• Brake pads (recommended replacement) × 1 — Use OEM specification
• DOT 4 brake fluid × 1 — 1 quart bottle minimum

Fluids

• DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen wheel lug nuts while vehicle is on ground (do not remove)
4. Remove reservoir cap from brake fluid master cylinder and extract approximately 1/3 of fluid with turkey baster to prevent overflow when compressing caliper piston
5. Raise front of vehicle with floor jack and support securely on jack stands placed on designated frame lift points
6. Remove wheel completely and set aside
7. Inspect brake components for wear, damage, or contamination before beginning work

Procedure

1. 1

   Remove brake caliper from bracket
   Locate the two caliper slide pin bolts on the rear of the caliper assembly. Using a socket wrench, remove both caliper slide pin bolts. Carefully lift the caliper off the brake pads and bracket. Do NOT disconnect the brake hose at this time. Support the caliper with a wire hanger or bungee cord attached to the suspension strut to prevent stress on the brake hose.
   Torque spec

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

   Disconnect brake hose from caliper
   Place a drain pan under the caliper to catch brake fluid. Using a flare nut wrench or box wrench, loosen and remove the banjo bolt securing the brake hose to the caliper. Note the position of the two copper crush washers (one on each side of the banjo fitting). Remove and discard both old copper washers. Immediately plug the brake hose opening with a rubber plug or clean rag to minimize fluid loss and prevent contamination. Remove the caliper completely from the vehicle.
   ⚠Brake fluid will drain from the hose. Have rags and drain pan ready. Clean any spilled fluid from painted surfaces immediately.
   Torque spec

   Brake Hose Banjo Bolt39 Nm (29 lb-ft)
3. 3

   Remove brake pads and hardware
   Remove both brake pads from the caliper bracket. Remove any anti-rattle clips, shims, or pad retaining springs and note their orientation for reinstallation. Inspect all hardware for damage or excessive wear and replace as needed.
4. 4

   Remove caliper bracket
   Locate the two large caliper bracket mounting bolts on the rear of the steering knuckle. These bolts are typically 17mm and may be very tight. If necessary, apply penetrating oil and allow to soak for several minutes. Using a breaker bar or impact wrench, remove both caliper bracket bolts. Remove the caliper bracket from the steering knuckle and rotor.
   ⚠These bolts are torque-critical and may require significant force to remove. Ensure proper socket engagement to avoid rounding bolt heads.
   Torque spec

   Caliper Bracket Bolts - Front120 Nm (88 lb-ft)
5. 5

   Clean mounting surfaces
   Using a wire brush, thoroughly clean the caliper bracket mounting surface on the steering knuckle. Remove all rust, corrosion, and debris. Clean the slide pin bores in the bracket if reusing old bracket hardware. Inspect the rotor mounting surface and hub for damage or excessive rust buildup.
6. 6

   Install new caliper bracket
   Apply a thin coat of medium-strength threadlocker to the threads of both new or cleaned caliper bracket bolts. Position the new caliper bracket onto the steering knuckle, ensuring proper alignment with the mounting holes. Thread both bracket bolts by hand to prevent cross-threading. Using a torque wrench, tighten both caliper bracket bolts to specification in an alternating pattern.
   ⚠️Proper torque is absolutely critical for safe brake operation. Use a calibrated torque wrench and verify final torque after initial tightening.
   Torque spec

   Caliper Bracket Bolts - Front120 Nm (88 lb-ft)
7. 7

   Prepare and install brake pads
   Apply a thin layer of silicone brake grease to the pad backing plate contact points on the caliper bracket (where pads slide). Do NOT apply grease to pad friction material or rotor surface. Install anti-rattle clips and shims in their original positions. Install both brake pads into the caliper bracket, ensuring they move freely in the bracket channels.
8. 8

   Reconnect brake hose to caliper
   Install NEW copper crush washers on both sides of the brake hose banjo fitting. Position the banjo fitting into the caliper inlet port, ensuring proper hose routing without kinks or twists. Thread the banjo bolt by hand, then tighten to specification using a torque wrench. Verify the brake hose has adequate clearance from suspension components and tire throughout full steering range.
   ⚠️New copper washers are mandatory. Reusing old washers will likely result in brake fluid leakage and potential brake failure.
   Torque spec

   Brake Hose Banjo Bolt39 Nm (29 lb-ft)
9. 9

   Compress caliper piston and reinstall caliper
   Using a C-clamp or brake piston tool, slowly compress the caliper piston fully into its bore. Position the caliper over the brake pads and onto the caliper bracket. Apply silicone brake grease to the slide pin bolt threads and sliding surfaces. Thread both slide pin bolts by hand, then torque to specification.
   ℹ️Monitor brake fluid reservoir while compressing piston - fluid level will rise. Remove fluid if necessary to prevent overflow.
   Torque spec

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

    Bleed brake system
    Fill brake fluid reservoir to MAX line with fresh DOT 4 brake fluid. Attach clear brake bleeding tubing to the bleeder screw on the caliper and place the other end in a container partially filled with brake fluid. Have an assistant pump the brake pedal 3-4 times and hold pressure. Open the bleeder screw 1/2 turn and allow fluid and air to escape until flow stops, then close bleeder screw. Repeat this process until no air bubbles appear in the tubing and only clean fluid flows. Tighten bleeder screw to specification. Top off brake fluid reservoir to MAX line.
    ⚠️Air in the brake system will cause reduced braking performance or complete brake failure. Continue bleeding until absolutely no air bubbles are present.
    ⚠Do not overtighten bleeder screw as it can strip easily. Use proper torque specification.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
11. 11

    Reinstall wheel and lower vehicle
    Clean wheel mounting surface on hub. Position wheel onto hub and thread all lug nuts by hand. Using a torque wrench in a star pattern, tighten lug nuts to specification. Lower vehicle from jack stands and remove stands. With vehicle on ground, perform final lug nut torque in star pattern.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Verify all brake components are properly secured and torqued
2. Check brake fluid reservoir level and top off to MAX line with DOT 4 brake fluid
3. Ensure brake hose has proper routing and clearance throughout full steering range
4. Verify no tools or parts have been left in wheel well or under vehicle

Verification

• With engine off, pump brake pedal repeatedly - it should feel firm and not sink to floor
• Start engine and verify brake pedal does not sink with sustained pressure
• Check for any brake fluid leaks around banjo bolt connection, bleeder screw, and caliper bracket area
• Perform a low-speed brake test in a safe area (5-10 mph) to verify proper brake operation before normal driving
• After first test drive, recheck all torque specifications and inspect for fluid leaks
• Monitor brake pedal feel over the next several days and re-bleed if pedal becomes soft
• Check brake fluid level after 50-100 miles of driving

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