| TUCSON(LM) >2011 > G 2.0 DOHC > Brake System > Brake System > Front Disc Brake>Repair procedures |

Removal
1. | Remove the front wheel & tire.
Tightening torque: 88.3 ~107.9 N.m (9.0 ~11.0 kgf.m, 65.1 ~79.6 lb-ft)
2. | Loosen the hose eyebolt (B) and caliper mounting bolts (C), then remove the front caliper assembly (A).
Tightening torque: Brake hose to caliper(B): 24.5 ~29.4 N.m (2.5 ~3.0 kgf.m, 18.1 ~21.7 lb-ft) Caliper assembly to knuckle(C): 78.5 ~98.1 N.m (8.0 ~10.0 kgf.m, 57.9 ~72.3 lb-ft)
3. | Remove the front brake disc by loosening the screws (A).
Replacement
Front brake pads
1. | Remove the brake hose mounting bracket bolt (A).
2. | Loosen the guide rod bolt (B) and pivot the caliper (A) up out of the way.
Tightening torque: 21.6 ~31.4 N.m (2.2 ~3.2 kgf.m, 15.9 ~23.1 lb-ft)
3. | Replace pad shim (D), pad retainers (C) and brake pads (B) in the caliper bracket (A).
Inspection
Front brake disc thickness check
1. | Check the brake pads for wear and fade.
2. | Check the brake disc for damage and cracks.
3. | Remove all rust and contamination from the surface, and measure the disc thickness at 8 points, at least, of same distance (5mm) from the brake disc outer circle.
Brake disc thickness [2WD] - Standard : 26 mm (1.02 in) - Service Limit : 24.4 mm (0.96 in) [4WD] - Standard : 28 mm (1.10 in) - Service Limit : 26.4 mm (1.04 in) Deviation: Less than 0.005mm (0.0002in)
4. | If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle.
Front Brake Pad Check
1. | Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value.
Pad thickness Standard value: 11 mm (0.43 in) Service limit: 2.0 mm (0.0787 in)
2. | Check that grease is applied, to sliding contact points and the pad and backing metal for damage.
Front brake disc runout check
1. | Place a dial gauge about 5mm (0.2 in.) from the outer circumference of the brake disc, and measure the runout of the disc.
Brake disc runout Limit: 0.025 mm (0.00098 in.) or less (new one)
2. | If the runout of the brake disc exceeds the limit specification, replace the disc, and then measure the runout again.
3. | If the runout does not exceed the limit specification, install the brake disc after turning it 180° and then check the runout of the brake disc again.
4. | If the runout cannot be corrected by changing the position of the brake disc, replace the brake disc.
Installation
1. | Installation is the reverse of removal.
2. | Use a SST (09581-11000) when installing the brake caliper assembly.
3. | After installation, bleed the brake system. (Refer to Brake system bleeding)