2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
2007 BRAKES
Brake System - Santa Fe
BRAKE SYSTEM
OPERATION AND LEAKAGE
CHECK
CHECK ALL OF THE FOLLOWING ITEMS
COMPONENTS CHECK
Component Procedure
Check brake operation by applying the brakes during a test drive. If the brakes do
Brake Booster (A) not work properly, check the brake booster. Replace the brake booster as an
assembly if it does not work properly or if there are signs of leakage.
Check brake operation by applying the brakes. Look for damage or signs of
fluid leakage. Replace the master cylinder as an assembly if the pedal does not
Piston cup and
work properly or if there is damage or signs of fluid leakage.
pressure cup
inspection (B) Check for a difference in brake pedal stroke between quick and slow brake
applications. Replace the master cylinder if there is a difference in pedal
stroke.
Look for damage or signs of fluid leakage. Replace the brake hose with a new one if
Brake hoses (C)
it is damaged or leaking.
Check brake operation by applying the brakes.
Caliper piston seal Look for damage or signs of fluid leakage. If the pedal does not work properly, the
and piston boots brakes drag, or there is damage or signs of fluid leakage, disassemble and inspect the
(D) brake caliper. Replace the boots and seals with new ones whenever the brake caliper
is disassembled.
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
Fig. 1: Brake System Operation Diagram
Courtesy of HYUNDAI MOTOR CO.
BRAKE SYSTEM BLEEDING
CAUTION: Do not reuse the drained fluid.
Always use genuine DOT 3 brake Fluid. Using a non-genuine DOT 3
brake fluid can cause corrosion and decrease the life of the system.
Make sure no dirt of other foreign matter is allowed to contaminate
the brake fluid.
Do not spill brake fluid on the vehicle, it may damage the paint; if
brake fluid does contact the paint, wash it off immediately with water.
The reservoir on the master cylinder must be at the MAX (upper) level
mark at the start of bleeding procedure and checked after bleeding
each brake caliper. Add fluid as required.
1. Make sure the brake fluid in the reservoir is at the MAX (upper) level line.
2. Have someone slowly pump the brake pedal several times, and then apply pressure.
3. Loosen the right-rear brake bleed screw (A) to allow air to escape from the system. Then tighten the bleed
screw securely.
4. Repeat the procedure for wheel in the sequence shown below unit air bubbles no longer appear in the
fluid.
5. Refill the master cylinder reservoir to MAX (upper) level line.
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
Fig. 2: Brake System Bleeding Sequence
Courtesy of HYUNDAI MOTOR CO.
Fig. 3: Identifying Right-Rear Brake Bleed Screw
Courtesy of HYUNDAI MOTOR CO.
BRAKE BOOSTER
COMPONENTS
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
Fig. 4: Identifying Brake Booster Components With Torque Specification
Courtesy of HYUNDAI MOTOR CO.
BRAKE BOOSTER OPERATING TEST
For simple checking of the brake booster operation, carry out the following tests
1. Run the engine for one or two minutes, and then stop it. If the pedal depresses fully the first time but
gradually becomes higher when depressed succeeding times, the booster is operating properly, if the
pedal height remains unchanged, the booster is inoperative.
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
Fig. 5: Identifying Brake Booster Operating Position
Courtesy of HYUNDAI MOTOR CO.
2. With the engine stopped, step on the brake pedal several times.
Then step on the brake pedal and start the engine. If the pedal moves downward slightly, the booster is in
good condition. If there is no change, the booster is inoperative.
Fig. 6: Identifying Booster Good Condition
Courtesy of HYUNDAI MOTOR CO.
3. With the engine running, step on the brake pedal and then stop the engine.
Hold the pedal depressed for 30 seconds. If the pedal height does not change, the booster is in good
condition, if the pedal rises, the booster is inoperative.
If the above three tests are okay, the booster performance can be determined as good.
Even if one of the above three tests is not okay, check the check valve, vacuum hose and booster for
malfunction.
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
Fig. 7: Identifying Booster Good Condition
Courtesy of HYUNDAI MOTOR CO.
REMOVAL
1. Remove the air cleaner assembly.
Fig. 8: Identifying Air Cleaner Assembly
Courtesy of HYUNDAI MOTOR CO.
2. Disconnect the vacuum hose (A).
3. Disconnect the brake fluid level switch connector (B) from the reservoir.
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
Fig. 9: Identifying Brake Fluid Level Switch Connector And Vacuum Hose
Courtesy of HYUNDAI MOTOR CO.
4. Remove the master cylinder. (Refer to MASTER CYLINDER)
5. Remove the snap pin (A) and joint pin (B).
Fig. 10: Identifying Snap Pin And Joint Pin
Courtesy of HYUNDAI MOTOR CO.
6. Remove the brake booster by loosening the mounting nuts.
Tightening torque Nm (kgf.m, lb-ft):
13 ~ 16 (1.3 ~ 1.6, 9.4 ~ 11.6)
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
Fig. 11: Identifying Brake Booster Mounting Nuts
Courtesy of HYUNDAI MOTOR CO.
INSPECTION
1. Inspect the check valve in the vacuum hose.
CAUTION: Do not remove the check valve from the vacuum hose.
2. Check the boot for damage.
INSTALLATION
1. Installation is the reverse of removal.
CAUTION: Before installing the pin, apply the grease to the joint pin.
Use a new snap pin whenever installing.
2. After installing, bleed the brake system. (Refer to BRAKE SYSTEM BLEEDING.)
3. Adjust the brake pedal height and free play. (Refer to BRAKE PEDAL HEIGHT AND FREE PLAY
ADJUSTMENT)
MASTER CYLINDER
COMPONENTS
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
Fig. 12: Identifying Master Cylinder Components
Courtesy of HYUNDAI MOTOR CO.
REMOVAL
1. Remove the air cleaner assembly.
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
Fig. 13: Identifying Air Cleaner Assembly
Courtesy of HYUNDAI MOTOR CO.
2. Disconnect the brake fluid level switch connector (A) and hose (B) from the reservoir.
Fig. 14: Identifying Brake Fluid Level Switch Connector
Courtesy of HYUNDAI MOTOR CO.
CAUTION: Do not spill brake fluid on the vehicle, it may damage the paint;
if brake fluid does contact the paint, wash it off immediately
with water.
3. Disconnect the brake tube from the master cylinder by loosening the tube flare nut (A).
Tightening torque Nm (kgf.m, lb-ft):
12.7 ~ 16.7 (1.3 ~ 1.7, 9.4 ~ 12.3)
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
4. Remove the master cylinder from the brake booster after loosening the mounting nuts (B).
Tightening torque Nm (kgf.m, lb-ft):
7.8 ~ 11.8 (0.8 ~ 1.2, 5.8 ~ 8.7)
Fig. 15: Identifying Master Cylinder Tube And Nuts
Courtesy of HYUNDAI MOTOR CO.
DISASSEMBLY
1. Remove the reservoir cap and drain the brake fluid into a suitable container.
2. Remove the fluid level sensor.
3. Remove the reservoir from the master cylinder, after remove mounting screw (A).
Fig. 16: Identifying Master Cylinder Screw
Courtesy of HYUNDAI MOTOR CO.
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
4. Remove the retainer ring (A) by using the snap ring pliers.
Fig. 17: Identifying Retainer Ring
Courtesy of HYUNDAI MOTOR CO.
5. Remove the primary piston assembly (A).
6. Remove the pin (C) with the secondary piston (B) pushed completely using a screwdriver. Remove the
secondary piston assembly (B).
Fig. 18: Identifying Primary And Secondary Piston Assembly With Pin
Courtesy of HYUNDAI MOTOR CO.
NOTE: Do not disassemble the primary and secondary piston assembly.
INSPECTION
1. Check the master cylinder bore for rust or scratching.
2. Check the master cylinder for wear or damage. If necessary, clean or replace the cylinder.
CAUTION: If the cylinder bore is damaged, replace the master cylinder
assembly.
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
Wash the contaminated parts in alcohol.
REASSEMBLY
1. Apply genuine brake fluid to the rubber parts of the cylinder kit and grommets.
2. Carefully insert the springs and pistons in the proper direction.
3. Press the piston with a screwdriver (A) and install the cylinder pin (B).
Fig. 19: Inserting Springs And Pistons In Proper Direction
Courtesy of HYUNDAI MOTOR CO.
4. Install the retainer ring (A) after installing primary piston assembly.
Fig. 20: Installing Retainer Ring On Primary Piston Assembly
Courtesy of HYUNDAI MOTOR CO.
5. Mount two grommets.
6. Install the reservoir on the cylinder.
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
INSTALLATION
1. Installation is the reverse of removal.
2. After installation, bleed the brake system. (Refer to BRAKE SYSTEM BLEEDING)
BRAKE LINE
COMPONENTS
Fig. 21: Identifying Brake Line Components With Torque Specification
Courtesy of HYUNDAI MOTOR CO.
REMOVAL
1. Remove the wheel & tire.
2. Remove the brake hose clip (A).
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
Fig. 22: Identifying Brake Hose Clip
Courtesy of HYUNDAI MOTOR CO.
3. Disconnect the brake tube by loosening the tube flare nut (A).
Tightening torque Nm (kgf.m, lb-ft):
12.7 ~ 16.7 (1.3 ~ 1.7, 9.4 ~ 12.3)
Fig. 23: Tightening Tube Flare Nut
Courtesy of HYUNDAI MOTOR CO.
4. Disconnect the brake hose (A) from the brake caliper by loosening the bolt.
Tightening torque Nm (kgf.m, lb-ft):
16.7 ~ 25.5 (1.6 ~ 2.6, 12.3 ~ 18.8)
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
Fig. 24: Identifying Brake Hose
Courtesy of HYUNDAI MOTOR CO.
INSPECTION
1. Check the brake tubes for cracks, crimps and corrosion.
2. Check the brake hoses for cracks, damage and fluid leakage.
3. Check the brake tube flare nuts for damage and fluid leakage.
INSTALLATION
1. Installation is the reverse of removal.
CAUTION: Use a new washer (A) whenever installing.
Fig. 25: Identifying Washer
Courtesy of HYUNDAI MOTOR CO.
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
2. After installation, bleed the brake system (Refer to BRAKE SYSTEM BLEEDING)
BRAKE PEDAL
COMPONENTS
Fig. 26: Identifying Brake Pedal Components With Torque Specification
Courtesy of HYUNDAI MOTOR CO.
BRAKE PEDAL HEIGHT AND FREE PLAY ADJUSTMENT
1. Disconnect the stop lamp switch (A) connector and loosen the stop lamp switch lock nut.
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
Fig. 27: Identifying Stop Lamp Switch Connector
Courtesy of HYUNDAI MOTOR CO.
2. Adjust the brake pedal height (A) as illustration below.
Pedal height: 214 mm (8.43 in)
Fig. 28: Identifying Brake Pedal Height
Courtesy of HYUNDAI MOTOR CO.
3. Adjust the stop lamp switch clearance and brake pedal free play.
Stop lamp clearance: 0.5 ~ 1.0 mm (0.02 ~ 0.04 in)
Pedal free play: 3.0 ~ 8.0 mm (0.12 ~ 0.31)
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
Fig. 29: Identifying Stop Lamp Switch Clearance And Brake Pedal Free Play
Courtesy of HYUNDAI MOTOR CO.
NOTE: Adjust the brake pedal free play using the stop lamp switch lock nut.
REMOVAL
1. Remove the lower crash pad.
Fig. 30: Identifying Lower Crash Pad
Courtesy of HYUNDAI MOTOR CO.
2. Disconnect the stop lamp switch (A) connector.
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
Fig. 31: Identifying Stop Lamp Switch Connector
Courtesy of HYUNDAI MOTOR CO.
3. Remove the snap pin (A) and joint pin (B).
4. Remove the brake pedal by loosen the joint bolt (C) and nut.
Tightening torque Nm (kgf.m, lb-ft):
24.5 ~ 34.3 (2.5 ~ 3.5, 18.1 ~ 25.3)
Fig. 32: Identifying Snap Pin And Joint Pin With Joint Bolt
Courtesy of HYUNDAI MOTOR CO.
INSTALLATION
1. Installation is the reverse of removal.
CAUTION: Before installing the pin, apply the grease to the joint pin.
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
Use a new snap pin whenever installing.
2. Check the brake pedal operation.
FRONT DISC BRAKE
COMPONENTS
Fig. 33: Identifying Front Disc Brake Components With Torque Specification (1 Of 2)
Courtesy of HYUNDAI MOTOR CO.
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
Fig. 34: Identifying Front Disc Brake Components With Torque Specification (2 Of 2)
Courtesy of HYUNDAI MOTOR CO.
REMOVAL
1. Remove the front wheel & tire.
Tightening torque Nm (kgf.m, Lb-ft):
88.3 ~ 107.9 (9.0 ~ 11.0, 65.1 ~ 79.6)
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
Fig. 35: Identifying Front Wheel And Tire With Nuts
Courtesy of HYUNDAI MOTOR CO.
2. Remove the split pin (A) and castle nut (B).
Tightening torque Nm (kgf.m, lb-ft):
200 ~ 260 (20 ~ 26, 145 ~ 188)
Fig. 36: Identifying Split Pin And Castle Nut
Courtesy of HYUNDAI MOTOR CO.
3. Loosen the hose eye-bolt (A) and caliper mounting bolts, then remove the front caliper assembly (B).
Tightening torque Nm (kgf.m, lb-ft):
Brake hose to caliper:
24.5 ~ 29.4 (2.5 ~ 3.0, 18.1 ~ 21.7)
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
Caliper assembly to knuckle:
78.5 ~ 98.1 (8.0 ~ 10.0, 57.9 ~ 72.3)
Fig. 37: Identifying Hose Eye-Bolt And Front Caliper Assembly
Courtesy of HYUNDAI MOTOR CO.
4. Remove the front brake disc by loosening the screws (A).
Fig. 38: Identifying Front Brake Disc Screws
Courtesy of HYUNDAI MOTOR CO.
REPLACEMENT
FRONT BRAKE PADS
1. Loosen the guide rod bolt (A) and pivot the caliper (B) up out of the way.
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
Fig. 39: Identifying Guide Rod Bolt
Courtesy of HYUNDAI MOTOR CO.
2. Replace shims (A), pad retainers (B), and brake pads (C).
Fig. 40: Identifying Shims, Pad Retainers And Brake Pads
Courtesy of HYUNDAI MOTOR CO.
3. Push the piston in the cylinder using a SST (09581-11000)
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
Fig. 41: Identifying SST (09581-11000)
Courtesy of HYUNDAI MOTOR CO.
4. Pivot the caliper down and tighten the guide rod bolt.
Tightening torque Nm (kgf.m, lb-ft):
21.6 ~ 31.4 (2.2 ~ 3.2, 15.9 ~ 23.1)
INSPECTION
1. Check the brake pads for wear and fade.
2. Check the brake disc for damage and cracks.
3. Check the thickness of the brake disc and run-out using a micrometer and a dial gauge on the part dotted
line in the illustration below.
Brake disc thickness
Standard: 28 mm (1.10 in)
Service limit: 26.4 mm (1.04 in)
Deviation: Less than 0.01 mm (0.00039 in)
Run-out
Standard: 0.03 mm (0.00118 in) or less
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
Fig. 42: Identifying Brake Disc Thickness
Courtesy of HYUNDAI MOTOR CO.
INSTALLATION
1. Installation is the reverse of removal.
2. Use a SST (09581-11000) when installing the brake caliper assembly.
Fig. 43: Identifying SST (09581-11000)
Courtesy of HYUNDAI MOTOR CO.
3. After installation, bleed the brake system. (Refer to BRAKE SYSTEM BLEEDING)
REAR DISC BRAKE
COMPONENTS
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
Fig. 44: Identifying Rear Disc Brake Components With Torque Specification
Courtesy of HYUNDAI MOTOR CO.
REMOVAL
1. Remove the rear wheel & tire.
Tightening torque Nm (kgf.m, lb-ft):
88.3 ~ 107.9 (9.0 ~ 11.0, 65.1 ~ 79.6)
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
Fig. 45: Identifying Rear Wheel And Tire With Nuts
Courtesy of HYUNDAI MOTOR CO.
2. Remove the split pin (A) and castle nut (B).
Tightening torque Nm (kgf.m, lb-ft):
200 ~ 260 (20 ~ 26, 145 ~ 188)
Fig. 46: Identifying Split Pin And Castle Nut
Courtesy of HYUNDAI MOTOR CO.
3. Loosen the hose eye-bolt (A) and caliper mounting bolts, then remove the rear caliper assembly.
Tightening torque Nm (kgf.m, lb-ft):
Brake hose to caliper:
24.5 ~ 29.4 (2.5 ~ 3.0, 18.1 ~ 21.7)
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
Caliper assembly to carrier:
78.5 ~ 98.1 (8.0 ~ 10.0, 57.9 ~ 72.3)
Fig. 47: Identifying Hose Eye-Bolt
Courtesy of HYUNDAI MOTOR CO.
4. Remove the rear brake disc by loosening the screws (A).
Fig. 48: Identifying Rear Brake Disc Screws
Courtesy of HYUNDAI MOTOR CO.
REPLACEMENT
REAR BRAKE PADS
1. Loosen the guide rod bolt (A) and pivot the caliper up out of the way.
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
Fig. 49: Identifying Guide Rod Bolt
Courtesy of HYUNDAI MOTOR CO.
2. Replace shims (A), pad retainers (B), and brake pads (C).
Fig. 50: Identifying Shims, Pad Retainers, And Brake Pads
Courtesy of HYUNDAI MOTOR CO.
3. Push the piston in the cylinder using a SST (09581-11000)
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
Fig. 51: Identifying SST (09581-11000)
Courtesy of HYUNDAI MOTOR CO.
4. Pivot the caliper down and tighten the guide rod bolt.
Tightening torque Nm (kgf.m, lb-ft):
21.6 ~ 31.4 (2.2 ~ 3.2, 15.9 ~ 23.1)
INSPECTION
1. Check the brake pads for wear and fade.
2. Check the brake disc for damage and cracks.
3. Check the thickness of the brake disc and run-out using a micrometer and a dial gauge on the part dotted
line in the illustration below.
Brake disc thickness
Standard: 11 mm (0.43 in)
Service limit: 9.4 mm (0.37 in)
Deviation: less than 0.01 mm (0.00039 in)
Run-out
Standard: 0.03 mm (0.00118 in) or less
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2007 Hyundai Santa Fe GLS
2007 BRAKES Brake System - Santa Fe
Fig. 52: Identifying Brake Disc Thickness
Courtesy of HYUNDAI MOTOR CO.
INSTALLATION
1. Installation is the reverse of removal.
2. Use a SST (09581-11000) when installing the brake caliper assembly.
Fig. 53: Identifying SST (09581-11000)
Courtesy of HYUNDAI MOTOR CO.
3. After installation, bleed the brake system. (Refer to BRAKE SYSTEM BLEEDING)
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