Brake Rotors - Rear Pair

This procedure covers the removal and replacement of both rear brake rotors on a 2015 Kia Forte with 1.8L I4 engine, including caliper removal and proper torque specifications.

Warnings

Tools required

Parts

• Rear brake rotor × 2 — Use OEM specification or equivalent - verify diameter and thickness
• Rotor set screws (if corroded) × 2 — M6 x 1.0 screw

Fluids

• DOT 4 Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level, solid surface and engage parking brake firmly
2. Place wheel chocks in front of both front wheels
3. Loosen rear wheel lug nuts 1/4 turn while vehicle is on ground (do not remove)
4. Lift rear of vehicle and secure on jack stands at manufacturer-recommended lift points
5. Remove rear wheels completely and set aside
6. Verify brake fluid reservoir cap is secure to prevent spillage during caliper compression

Procedure

1. 1

   Compress brake caliper piston
   Open the brake fluid reservoir cap slightly to prevent pressure buildup. Use a C-clamp or brake caliper compression tool to slowly compress the caliper piston fully into its bore. This creates clearance to remove the caliper. Monitor the brake fluid reservoir to ensure it does not overflow; remove fluid with a turkey baster if necessary. Re-secure the reservoir cap when finished.
   ⚠Old brake fluid may overflow from reservoir during piston compression. Have rags ready and dispose of brake fluid properly.
2. 2

   Remove caliper slide pin bolts
   Locate the two caliper slide pin bolts on the rear of the caliper assembly (typically 17mm). Remove both slide pin bolts completely. The caliper should now be free to pivot away from the rotor.
   ℹ️Note the condition of the slide pin bolt rubber boots. Replace if torn or damaged to prevent contamination.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
3. 3

   Remove and secure brake caliper
   Carefully lift the caliper off the rotor and bracket assembly. Immediately secure the caliper to the suspension or chassis using wire or a bungee cord to prevent any tension on the brake hose. Do not let it hang freely. Inspect the brake hose for cracks, bulges, or damage.
   ⚠️Never allow caliper to hang by brake hose. Hose damage can cause catastrophic brake failure.
4. 4

   Remove caliper bracket
   Locate the two caliper bracket bolts securing the bracket to the steering knuckle (typically 19mm). These bolts are very tight and may require a breaker bar. Remove both bolts completely and remove the caliper bracket. Keep the brake pad shims and anti-rattle clips if reusing brake pads.
   ⚠Caliper bracket bolts are torqued very tightly. Ensure tool is properly seated to avoid rounding bolt heads.
   Torque spec

   Caliper Bracket Bolts97 Nm (71 lb-ft)
5. 5

   Remove rotor set screw and rotor
   If present, remove the Phillips head set screw securing the rotor to the hub (these often corrode and may require an impact driver or careful drilling if stripped). Once the set screw is removed, pull the rotor straight off the hub. If the rotor is stuck due to rust, tap it from behind with a rubber mallet while rotating it, or use penetrating oil and thread bolts into the threaded holes (if present) to force it off.
   ⚠Rotors may be seized by corrosion. Never strike the rotor face directly. Use proper puller holes if rotor will not release.
   Torque spec

   Rotor Set Screws6 Nm (5 lb-ft)
6. 6

   Clean hub surface
   Use a wire brush to thoroughly clean the hub mounting surface, removing all rust, scale, and debris. This ensures the new rotor seats flat against the hub. Clean the wheel mounting surface as well. Apply a thin coat of anti-seize compound to the hub surface (avoid getting any on the wheel studs or rotor friction surfaces).
7. 7

   Install new rotor
   Remove any protective coating from the new rotor using brake cleaner and a clean cloth (rotors are shipped with oil coating to prevent rust). Wipe both friction surfaces thoroughly. Slide the new rotor onto the hub, ensuring it seats completely flat. Install the rotor set screw and tighten to specification to hold the rotor in place during assembly.
   ⚠New rotors have a protective oil coating that MUST be removed completely or brake performance will be severely compromised.
   Torque spec

   Rotor Set Screws6 Nm (5 lb-ft)
8. 8

   Reinstall caliper bracket
   Position the caliper bracket over the rotor and align with the mounting holes on the steering knuckle. Install both caliper bracket bolts and tighten to the specified torque value in a criss-cross pattern. Ensure bracket is seated flush against the knuckle.
   ⚠️Caliper bracket bolts are CRITICAL safety fasteners. Torque wrench use is mandatory. Do not estimate torque.
   Torque spec

   Caliper Bracket Bolts97 Nm (71 lb-ft)
9. 9

   Reinstall brake caliper
   Remove the wire or bungee cord supporting the caliper. Clean the caliper slide pins and apply a thin coat of silicone brake grease to the pin shafts (not rubber boots). Position the caliper over the rotor and bracket, ensuring brake pads align with rotor surfaces. Install both slide pin bolts and tighten to specification.
   ⚠Use only silicone brake grease on slide pins. Other lubricants can swell rubber components and cause caliper seizure.
   Torque spec

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

    Repeat for opposite side
    Perform steps 1 through 9 on the opposite rear wheel to replace the second rotor. Both rear rotors must be replaced as a pair to maintain proper brake balance.
11. 11

    Reinstall wheels and lower vehicle
    Install both rear wheels and hand-tighten all lug nuts in a star pattern. Lower the vehicle until the tires just contact the ground (still supported partially by jack). Torque all lug nuts to specification in a star pattern. Fully lower the vehicle and remove jack stands.
    ⚠️Improperly torqued lug nuts can cause wheel detachment. Use torque wrench and star pattern sequence.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)
12. 12

    Restore brake pedal and check fluid level
    With vehicle on ground and parking brake released, pump the brake pedal slowly 10-15 times until firm pedal is achieved. This repositions the caliper pistons against the new rotors. Check the brake fluid reservoir and top off to the MAX line with DOT 4 brake fluid if needed. Secure reservoir cap.
    ⚠️DO NOT start vehicle or attempt to drive until a firm brake pedal is achieved. A soft pedal indicates air in system or piston not seated.

Reassembly

1. Torque specifications are CRITICAL for brake system safety - verify all fasteners are properly torqued
2. Ensure no tools or parts are left in wheel wells before test drive
3. Verify parking brake operation is normal before driving

Verification

• With engine running, pump brakes several times and verify firm, consistent pedal feel with no excessive travel
• Check for any brake fluid leaks around calipers, hoses, and reservoir
• Perform a low-speed test drive (under 15 mph in safe area) to verify brakes engage smoothly without pulling, noise, or vibration
• Perform 20-30 moderate stops from 30-40 mph to properly bed-in the new rotors (avoid hard braking during first 200 miles)
• Re-check all lug nut torque after first 50 miles of driving
• Monitor brake fluid level over the next few days to ensure no leaks are present

Related trouble codes on this vehicle

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