Kia Sorento: Rear Brake Disc Repair procedures

Kia Sorento (MQ4, 2021-2026) Service Manual / Brake System / Brake System / Rear Brake Disc Repair procedures

Removal

Release the parking brake.

•

EPB Apply : Perform the order below with the KDS.

(S/W Management → ABSESP - Braking Control → Brake Pad Change Mode)

Refer to the KDS screen for operating conditions and details

•	EPB None Apply : Release the parking brake pedal and parking brake cable is loose.

2.	Disconnect the (-) battery terminal.

3.	Remove the rear wheel and tire. (Refer to Suspension System - "Wheel")

Disconnect the EPB connector or parking brake cable.

•	EPB Apply : Disconnect the EPB connector (A).

•	EPB None Apply : Remove the parking brake cable (B), after removing the clip (A).

Remove the guide rod bolt (A) and then pivot the caliper body (B) up out of the way.

Tightening torque :

37.2 - 41.1 N·m (3.8 - 4.2 kgf·m, 27.4 - 30.3 lb·ft)

Brake System — Brake System / Rear Brake Disc / Repair procedures / Removal illustration

6.	Remove the brake pad (A).

7.	Remove the pad retainer (A).

Remove the caliper carrier (B) by removing the flange bolts (A).

Tightening torque :

98.1 - 117.6 N·m (10.0 - 12.0 kgf·m, 72.3 - 86.8 lb·ft)

Brake System — Brake System / Rear Brake Disc / Repair procedures / Removal illustration

•	Fix the caliper assembly with a wire.

•	Do not reuse the flange bolts.

Remove the rear brake disc (B) by removing the screws (A).

Tightening torque :

4.9 - 5.8 N·m (0.5 - 0.6 kgf·m, 3.6 - 4.3 lb·ft)

Brake System — Brake System / Rear Brake Disc / Repair procedures / Removal illustration

Inspection

Disc cleaning before inspection

1.	Check the brake disc for rust.

Spray the cleaing solution on rusted surface of disc.

Cleaning solution : Water-Detergent [Water : 0.08 gal (300 ml) Detergent : 0.004 gal (15 ml)]

3.	Drive the vehicle up to 30 MPH and depress the brake up to stop for complete repeat more than 5 cycles.

4.	Clean the disc with water.

5.	Visually verify that rust is completely removed.

6.	If rust has not been removed, repeat the procedure above.

Rear Brake Disc Thickness Check

1.	Check the brake pads for wear and fade.

2.	Check the brake disc for damage and cracks.

Remove all rust and contamination from the surface, and measure the disc thickness at 24 points, at least, at the same distance apart (10 mm) from the brake disc outer circle.

Rear Brake disc thickness

- For 16 inch wheel Standard : 11 mm (0.43 in.)

- For 16 inch wheel Service Limit : 9.0 mm (0.35 in)

DTV (Disc Thickness Variation) :

Circumference direction : Less than 0.005 mm (0.00020 in.)

Radial direction : Less than 0.010 mm (0.00040 in.)

Brake System — Brake System / Rear Brake Disc / Repair procedures / Inspection illustration

if the measured DTV larger than the limit and thickness thicker than the service limit of the disc, skim the brake disc.

•	Skim the disc according to the method of using each skimming lathe. (On-car mounting or external device)

•	Do not skim the brake disc when it reaches the service limit.

5.	If the brake disc is thinner than the service limit, replace the brake disc.

Rear Brake Disc Runout Check

Place a dial gauge about 10 mm (0.4 in.) from the outer circumference of the brake disc, and measure the runout of the disc.

Brake disc runout

Limit : 0.055 mm (0.0021 in.) or less (new one)

Brake System — Brake System / Rear Brake Disc / Repair procedures / Inspection illustration

if the measured disc runout larger than the limit and thickness thicker than the service limit of the disc, skim the brake disc and measure the runout again.

•	Skim the disc according to the method of using each skimming lathe. (On-car mounting or external device)

•	Do not skim the brake disc when it reaches the service limit.

3.	If the runout of the brake disc still exceeds the limit specification, replace the disc, and then measure the runout again.

Installation

Install in the reverse order of removal.

•	Be careful not to tilt the piston when inserting the piston.

•	Press the piston by rotating it clockwise. [EPB Apply]

•	Press the piston clockwise using a SST (09580-0U000). [EPB None Apply]

•	Do not apply excessive force when inserting the piston.

•	Rotate the piston slowly to prevet damage to the piston boot.

•	Before installing the caliper body, check the position of the piston groove. [EPB Apply] [EPB None Apply]

After installing the rear caliper, perform “Brake Pad Replacement Mode” using the KDS.

•

EPB Apply : Perform the order below with the KDS.

(S/W Management → ABSESP - Braking Control → Brake Pad Change Mode)

Refer to the KDS screen for operating conditions and details

•	EPB None Apply : After disassembling/assembling the caliper body or replacing the brake caliper, parking brake cable or brake disc, re-adjust the parking brake. (Refer to Parking Brake System - "Parking Brake Pedal Assembly")

3.	Apply the parking brake several times and check for normal operation.

4.	Check if the parking brake is operating normally.

Rear Brake Disc Components and Components Location

Components [EPB Apply] 1. Rear brake disc2. Rear hub carrier 3. Rear brake caliper [EPB None Apply] 1. Rear brake disc2. ...

Brake Pad Repair procedures

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Kia Sorento: Rear Brake Disc Repair procedures

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