The Hyundai Sonata debuted in the American market in 1989. The model was redesigned for model years 1995, 1999, 2006, and again for 2011. Originally a low-cost family sedan, the model has evolved into a competitive full-featured sedan while still remaining relatively inexpensive. All Sonatas are fitted with front disc brakes, and while the design varies slightly the same service procedures apply to all models.
Park the vehicle on a firm, level surface. Set the parking brake. Loosen the wheel lug nuts about one-half turn and then jack up the vehicle. Support the vehicle securely on an axle stand. Completely remove the lug nuts and pull the wheel off.
Remove the two caliper guide bolts. Roll the caliper back and forth a few times to force the brake pads apart slightly, then lift the caliper off the disc and hang it out of the way on a wire hook of bungee cord. Be careful to not damage the flexible brake hose.
Slide the brake pads and shims out of the caliper.
Push the caliper piston back into the cylinder with a piston retractor. Place the retractor spindle swivel on the piston face and the metal plate on the inner surface of the outer caliper frame. Tighten the spindle to force the piston back into the cylinder bore. Be careful not to damage the piston rubber seal.
Pull the disc off the hub. If difficult to remove, thread an 8 mm bolt into the hole on the disc face, and tighten the bolt to force the disc off the hub.
Measure the thickness of the brake pad linings. The shop manual specifies a minimum lining thickness of 0.08 of an inch for model year 2005 and earlier, and 0.12 of an inch for model year 2006 and later. If the lining thickness is less than the specified minimum, or if the linings are damaged or unevenly worn, then replace the pads.
Measure the thickness of the brake disc with a brake micrometer at several places around the disc. The minimum allowable disc thickness is stamped into the rim of the disc. If the measured disc thickness is below the specified minimum, or if the disc is warped, cracked, or shows other severe damage then replace the disc. Minor damage to the disc can be refurbished by machining at a brake shop or auto parts supply store.
Follow the steps in reverse order to reassemble the bake. Clean the caliper guide bolts with brake cleaning fluid and then liberally coat them with brake grease before reinserting them in the caliper mounts. Start the vehicle and test the brake operation. Replace the wheel and lower the vehicle.
