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

Warnings

Tools required

Parts

• Rear brake caliper assembly × 1 — Use OEM specification
• Brake line banjo bolt copper washers × 2 — Use OEM specification
• Brake pads (if needed) × 1 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 1 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Loosen rear wheel lug nuts while vehicle is on ground, but do not remove
3. Raise rear of vehicle with floor jack and support securely on jack stands rated for vehicle weight
4. Remove rear wheel completely
5. Locate brake fluid reservoir under hood and remove cap to facilitate fluid flow during caliper removal
6. Place absorbent pads or cardboard under work area to catch brake fluid spills

Procedure

1. 1

   Prepare caliper for removal
   Locate the brake caliper on the rear of the rotor. Clean the area around the brake line banjo bolt connection at the top of the caliper using brake cleaner to prevent contamination when disconnecting. Position a drain container below the caliper to catch brake fluid.
2. 2

   Disconnect brake line from caliper
   Using a 12mm wrench, carefully loosen and remove the brake line banjo bolt from the rear caliper. Be prepared for brake fluid to drain. Remove the bolt completely and immediately plug the brake line opening with a clean lint-free cloth or rubber plug to minimize fluid loss and prevent contamination. Remove and discard both copper crush washers from the banjo bolt.
   ⚠Brake fluid will begin draining immediately upon loosening the banjo bolt. Have drain container positioned properly.
3. 3

   Remove caliper mounting bolts
   Locate the two caliper mounting bolts on the rear side of the caliper (accessed from behind the caliper assembly). Using a 17mm socket, remove both caliper mounting bolts completely. The caliper may be seized to the bracket; gently work it free if necessary.
4. 4

   Remove old caliper
   Carefully lift the caliper off the brake rotor and bracket. If the brake pads are staying with the bracket, note their orientation and remove them. Inspect the caliper bracket for wear or damage. Set the old caliper aside with the open brake line port facing upward to minimize fluid loss.
5. 5

   Prepare new caliper for installation
   Remove any shipping plugs or protective covers from the new caliper. If the caliper piston is not fully retracted, use a C-clamp or brake caliper tool to compress it fully into the bore. Ensure the piston boot is not damaged during compression. Clean the caliper mounting surfaces with brake cleaner.
6. 6

   Install brake pads and position new caliper
   If brake pads were removed, install them into the caliper bracket in their correct orientation (inner and outer pads are different). Apply a thin layer of brake lubricant to pad backing plates where they contact the bracket. Position the new caliper over the brake rotor and bracket, aligning the mounting bolt holes.
7. 7

   Install and torque caliper mounting bolts
   Insert both caliper mounting bolts and thread them by hand to ensure proper engagement. Using a torque wrench and 17mm socket, tighten both mounting bolts to the specified torque in a criss-cross pattern. Verify the caliper is seated properly against the bracket.
8. 8

   Connect brake line to new caliper
   Remove the plug or cloth from the brake line. Install one NEW copper crush washer on each side of the banjo fitting (one against the caliper body, one under the bolt head). Position the banjo fitting into the caliper port, ensuring the brake hose is not twisted. Insert the banjo bolt and thread by hand. Using a 12mm wrench and torque wrench, tighten the brake line banjo bolt to the specified torque.
   ⚠️Both copper crush washers MUST be new. Reusing old washers will cause brake fluid leaks and brake system failure.
   Torque spec

   Brake Line Banjo Bolt25 Nm (18 lb-ft)
9. 9

   Bleed rear brake caliper
   Locate the bleeder screw on the rear of the caliper. Attach a clear vinyl hose to the bleeder screw and submerge the other end in a container partially filled with clean DOT 4 brake fluid. Have an assistant pump the brake pedal 3-5 times and hold pressure. Open the bleeder screw 1/4 to 1/2 turn using an 8mm wrench while pedal is held down. Close the bleeder screw before the assistant releases the pedal. Repeat this process until no air bubbles appear in the vinyl hose and only clean fluid flows. Check and top off the master cylinder reservoir frequently during bleeding to prevent introducing more air.
   ⚠️Never allow the brake fluid reservoir to run empty during bleeding, as this will introduce air into the entire brake system.
   Torque spec

   Bleeder Screw10 Nm (7 lb-ft)
10. 10

    Complete brake system bleeding
    After bleeding the rear caliper that was replaced, bleed the opposite rear caliper using the same procedure to ensure no air has entered that side. Follow standard brake bleeding sequence: right rear, left rear, right front, left front. Ensure firm brake pedal feel is achieved. Top off brake fluid reservoir to MAX line with fresh DOT 4 brake fluid and reinstall reservoir cap.
    ⚠️A spongy or low brake pedal after bleeding indicates air remains in the system. Do NOT drive the vehicle until a firm pedal is achieved.
11. 11

    Reinstall wheel and lower vehicle
    Reinstall the rear wheel, threading lug nuts by hand first to ensure proper seating. Tighten lug nuts in a star pattern with a lug wrench, but do not torque fully yet. Lower the vehicle until the tire just contacts the ground but the suspension is not fully loaded. Using a torque wrench, tighten the lug nuts to specification in a star pattern. Fully lower the vehicle and remove jack stands.

Reassembly

1. Verify all brake line connections are tight and show no signs of leaking
2. Double-check that brake fluid reservoir is filled to MAX line with DOT 4 fluid
3. Ensure no tools or parts have been left in the wheel well area
4. Wipe down any brake fluid spills from components and painted surfaces

Verification

• Start the engine and pump the brake pedal several times. The pedal should feel firm and consistent within 2-3 pumps. A soft or spongy pedal indicates air in the system and requires additional bleeding
• With the engine running, apply firm brake pressure and hold for 30 seconds. The pedal should not slowly sink to the floor, which would indicate a leak
• Visually inspect the new caliper, brake line banjo bolt connection, and bleeder screw for any signs of brake fluid leakage
• Perform a low-speed test drive in a safe area (parking lot) to verify proper brake operation. The vehicle should brake smoothly without pulling to one side
• After test drive, re-inspect all connections for leaks and verify brake fluid level has not dropped
• Road test at normal speeds in a safe area and verify full braking capability before returning to normal driving. Apply brakes firmly from 30-40 mph multiple times to seat the pads
• Re-check brake fluid level after 24 hours and top off if necessary. Some caliper piston movement during initial use may lower the reservoir level slightly

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