21-BR-002H

GROUP
NUMBER
BRAKES
Technical Service Bulletin
SUBJECT:
DATE
21-BR-002H
MODEL(S)
MARCH 2021
ALL
BRAKE SERVICE BEST PRACTICE RECOMMENDATIONS
This TSB supersedes 10-BR-001 to include new grease recommendations and brake service
best practices.
Description: This bulletin provides best practice recommendations when performing brake service
procedures.
Applicable Vehicles: All Hyundai vehicles
Table of Contents:
Warranty Information:............................................................................................2
Recommended Tools: ...........................................................................................2
Service Procedure:................................................................................................3
Front and Rear Brake Rotors ............................................................................3
Front Brake Calipers/Pads: FLOATING TYPE ONLY........................................4
Front Brake Calipers/Pads: FIXED TYPE ONLY ...............................................7
Rear Brake Calipers/Pads .................................................................................9
Rear Brake Drums/Shoes/Components .......................................................... 15
Brake Fluid Service ......................................................................................... 17
Brake Caliper Fluid Inspection ......................................................................... 18
Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair
BRAKE SERVICE BEST PRACTICE RECOMMENDATIONS
SUBJECT:
Warranty Information:
Normal warranty applies.
Recommended Tools:
NAME
PART NUMBER
PHOTO
On-car Brake Lathe
PFM 9.0 or higher version
by PRO-CUT
Air Bleeding Tool
Contact Bosch
09580-3D100
REMARK

Tool is available
through Bosch:
1-866-539-4248

Use as directed in the
vehicle’s shop manual or
TSB(s).
Previously provided to all
dealers as essential tools.
To order a replacement
contact Bosch:
1-866-539-4248

Active Hydraulic Boost (AHB)
Brake Air Bleeding Tool
Adapter
Brake Cleaner

09580-3D200
00232-19077
-
Brake Fluid,
DOT 3
12 oz
(354.9 mL)
00232-19033
-
Brake Fluid,
DOT 4
12 oz
(355 mL)
00232-19053
-
Copper Anti-Seize
Brake Lube
3M 08945
00232-19086
-

Dealer provided. Nonreimbursable shop
supplies.

Use fluid as specified in
the vehicle’s shop manual.

Use as directed in the
vehicle’s shop manual or
TSB(s).
Dealer provided. Nonreimbursable shop
supplies.


Silicone Paste
3M 08946

00232-19087

TSB #: 21-BR-002H
Silicone lubricant specified
for caliper slide pins.
Use as directed in the
vehicle’s shop manual or
TSB(s).
Dealer provided. Nonreimbursable shop
supplies.
Page 2 of 19
SUBJECT:
BRAKE SERVICE BEST PRACTICE RECOMMENDATIONS
SUBJECT:
Service Procedure:
Refer to the applicable vehicle shop manual or TSBs for service details.
Front and Rear Brake Rotors
NOTICE



1.
Always follow the brake lathe manufacturer’s recommendations for proper machining.
It is recommended to use an “on-car” brake lathe.
For more information on brake rotor service, refer to the applicable vehicle shop manual.
Measure rotor thickness BEFORE and
AFTER machining to ensure the brake rotor
is within specification.



Refer to the applicable vehicle shop
manual for minimum thickness.
When measuring the brake rotor for
minimum service thickness and runout,
remove all surface contamination and
corrosion to ensure an accurate
measurement.
Measure the thickness at 8 points (every
45 degrees) around the rotor, 5-10mm or
0.2-0.4” inboard of the outer edge.
Record these measurements on the
repair order sheet.
Measurement locations around rotor
2.
After machining, re-install the rotor (if removed) and caliper. Then, inspect the rotor runout.
 Refer to the applicable vehicle shop manual for recommended runout tolerance.
 Mount a dial indicator on the brake rotor 5-10mm or 0.2-0.4” inboard of the outer edge.
Record this measurement on the repair order sheet.
3.
Verify that the rotor is free of grease or other contamination. Clean with brake cleaner if
necessary.
4.
When re-installing the wheels, tighten the lug nuts in a star pattern to the torque specification
in the appropriate vehicle shop manual. This reduces runout from occurring.
5.
Tighten all bolts to the torque specification recommended in the appropriate vehicle
shop manual.
6.
After installing the machined rotors or installing new rotors, perform a brake burnishing
procedure.
1. Drive the vehicle and accelerate to 50 mph.
Apply the brakes using moderate force (about 0.3g deceleration rate), and slow the
vehicle to 10 mph. This action will take approximately 6 seconds.
2. With as little cooling time as possible, repeat this braking event 10 times.
TSB #: 21-BR-002H
Page 3 of 19
SUBJECT:
BRAKE SERVICE BEST PRACTICE RECOMMENDATIONS
SUBJECT:
Front Brake Calipers/Pads: FLOATING TYPE ONLY
NOTICE

1.
For more information regarding brake caliper and pad service, refer to the applicable vehicle
shop manual.
When performing the brake service on
floating type calipers, always remove, clean,
and inspect the caliper slide pins and boots.
Apply Silicone Paste, P/N 00232-19087 to
the caliper slide pins before reinstallation.
NOTICE




This procedure does not apply to
fixed-type calipers.
Use caliper slide pin recommended
lubricant.
Do not over-lubricate the slide pins.
If too much lubricant is applied to the
slide pins, air can be trapped at the
end of the pin creating an “air spring”.
This condition causes the caliper/pad
assembly to drag on the rotor.
!
!
CAUTION
Do not hang the caliper with the brake
hose.
2.
Remove the pads, and clean the pad backing plate and insulators/shims of debris.
Never reuse shims on new pads.
Inspect the pad friction surface for even wear and pad thickness. Refer to the applicable
vehicle shop manual for service limits.
Grease should not be applied to the pad backing plate unless instructed by the shop manual
or TSB(s), as it could trap debris, and increase the chance of noise or dragging.
TSB #: 21-BR-002H
Page 4 of 19
SUBJECT:
SUBJECT:
3.
BRAKE SERVICE BEST PRACTICE RECOMMENDATIONS
Remove the pad retainers, and clean the
contact surface of the caliper from debris
and corrosion. Use a wire brush if
necessary. Apply a light coat of Copper
Anti-Seize Brake Lube, P/N 00232-19086,
(A) to prevent further corrosion.
Clean and inspect the retainers if the pads
are reused. Discard damaged retainers.
Always use the retainers included with the
new pads.
A
4.
Inspect the caliper for brake fluid leaks.
Follow the Brake Caliper Fluid Inspection
procedure on page 18.
NOTICE
If a fluid leak is found at the banjo bolt
area between the brake line and the
caliper, replace the copper washers on
the banjo fitting.
TSB #: 21-BR-002H
Page 5 of 19
SUBJECT:
SUBJECT:
BRAKE SERVICE BEST PRACTICE RECOMMENDATIONS
5.
When re-installing the brake pads, install the
pad with the wear indicator on the inside, as
shown.
6.
Tighten all bolts to the torque specification recommended in the appropriate vehicle
shop manual.
TSB #: 21-BR-002H
Page 6 of 19
SUBJECT:
BRAKE SERVICE BEST PRACTICE RECOMMENDATIONS
SUBJECT:
Front Brake Calipers/Pads: FIXED TYPE ONLY
NOTICE

1.
For more information regarding brake caliper and pad service, refer to the applicable vehicle
shop manual.
When performing the brake service on fixed
type calipers, always remove and clean the
guide pins (B) and locking retainers (C)
using a non-abrasive method.
Inspect the pins for deformation or corrosion
that would inhibit the pads from moving
freely. It is not recommended to grease the
pins unless instructed by the shop manual or
TSB(s).
!
!
B
C
CAUTION
Do not hang the caliper with the brake
hose.
2.
Remove the pads, and clean the pad backing plate and insulators/shims of debris.
Never reuse shims on new pads.
Inspect the pad friction surface for even wear and pad thickness. Refer to the applicable
vehicle shop manual for service limits.
Grease should not be applied to the pad unless instructed by the shop manual or TSB(s), as
it could trap debris, and increase the chance of noise or dragging.
TSB #: 21-BR-002H
Page 7 of 19
SUBJECT:
SUBJECT:
3.
BRAKE SERVICE BEST PRACTICE RECOMMENDATIONS
Clean and inspect the pad springs (D) if the
pads are reused. Discard damaged springs.
Always use the parts included with new
pads.
D
4.
Inspect the caliper for brake fluid leaks.
Follow the Brake Caliper Fluid Inspection
procedure on page 18.
NOTICE
If a fluid leak is found at the banjo bolt
area between the brake line and the
caliper, replace the copper washers on
the banjo fitting.
5.
Tighten all bolts to the torque specification recommended in the appropriate vehicle
shop manual.
TSB #: 21-BR-002H
Page 8 of 19
SUBJECT:
SUBJECT:
BRAKE SERVICE BEST PRACTICE RECOMMENDATIONS
Rear Brake Calipers/Pads
NOTICE

For more information regarding rear brake service, refer to the applicable vehicle shop manual.
1a.
When servicing rear brakes on vehicles
equipped with an Electronic Parking Brake
(EPB), the Brake Pad Change Mode function
must be performed to release the rear
calipers before the caliper is removed.
1b.
Disconnect the EPB actuator (A) before
removing the caliper from the bracket.
1c.
If replacing the pads, retract the caliper
piston by rotating it.
TSB #: 21-BR-002H
Page 9 of 19
SUBJECT:
SUBJECT:
1d.
BRAKE SERVICE BEST PRACTICE RECOMMENDATIONS
Replace and reinstall parts in reverse order
of removal.
NOTICE
Tighten all bolts to the torque
specification recommended in the
appropriate vehicle shop manual.
Use the Brake Pad Change Mode in the
GDS-M to apply and release the EPB.
Repeat the apply/release function three
times.
1e.
After completing the Brake Pad Change
Mode, perform the Assembly Check (ECU
replacement) function.
Also perform this function after replacing the
rear pads, caliper, EPB actuator, or EPB
ECU.
TSB #: 21-BR-002H
Page 10 of 19
SUBJECT:
SUBJECT:
BRAKE SERVICE BEST PRACTICE RECOMMENDATIONS
TSB #: 21-BR-002H
Page 11 of 19
SUBJECT:
SUBJECT:
BRAKE SERVICE BEST PRACTICE RECOMMENDATIONS
2.
When servicing rear brakes on vehicles with
a manual parking brake, the piston may
need to be retracted by rotating the piston.
3.
When performing the brake service, always
remove, clean, and inspect the caliper slide
pins and boots.
Apply Silicone Paste, P/N 00232-19087 to
the caliper slide pins before reinstallation.
NOTICE




This procedure does not apply to
fixed-type calipers.
Use caliper slide pin recommended
lubricant.
Do not over-lubricate the slide pins.
If too much lubricant is applied to the
slide pins, air can be trapped at the
end of the pin creating an “air spring”.
This condition causes the caliper/pad
assembly to drag on the rotor.
!
!
CAUTION
Do not hang the caliper with the brake
hose.
TSB #: 21-BR-002H
Page 12 of 19
SUBJECT:
SUBJECT:
4.
BRAKE SERVICE BEST PRACTICE RECOMMENDATIONS
Remove the pads, and clean the pad backing plate and insulators/shims of debris.
Never reuse shims on new pads.
Inspect the pad friction surface for even wear and pad thickness. Refer to the applicable
vehicle shop manual for service limits.
Grease should not be applied to the pad backing plate unless instructed by the shop manual
or TSB(s), as it could trap debris, and increase the chance of noise or dragging.
5.
Remove the pad retainers, and clean the
contact surface of the caliper from debris
and corrosion. Use a wire brush if
necessary. Apply a light coat of Copper
Anti-Seize Brake Lube, P/N 00232-19086,
to prevent further corrosion (E).
Clean and inspect the retainers if the pads
are reused. Discard damaged retainers.
Always use the retainers included with the
new pads.
E
6.
Inspect the caliper for brake fluid leaks.
Follow the Brake Caliper Fluid Inspection
procedure on page 18.
TSB #: 21-BR-002H
Page 13 of 19
SUBJECT:
SUBJECT:
BRAKE SERVICE BEST PRACTICE RECOMMENDATIONS
NOTICE
If a fluid leak is found at the banjo bolt
area between the brake line and the
caliper, replace the copper washers on
the banjo fitting.
7.
When re-installing the brake pads, install the
pad with the wear indicator on the inside, as
shown.
8.
Tighten all bolts to the torque specification recommended in the appropriate vehicle
shop manual.
TSB #: 21-BR-002H
Page 14 of 19
SUBJECT:
BRAKE SERVICE BEST PRACTICE RECOMMENDATIONS
SUBJECT:
Rear Brake Drums/Shoes/Components
NOTICE


1.
Always follow the brake lathe manufacturer’s recommendations for proper machining.
For more information on brake drum service, refer to the applicable vehicle shop manual.
Measure the inside diameter and runout of
the drum BEFORE and AFTER machining to
ensure the brake rotor is within specification.


Refer to the applicable vehicle shop
manual for service limits.
When measuring the drum, remove all
surface contamination and corrosion to
ensure an accurate measurement.
2.
Clean all drum brake assembly components
to inspect for wear and leaks.
3.
Debris on the wheel cylinder and boots is not
an immediate indication that the wheel
cylinder is leaking. Carefully inspect the
wheel cylinder for leaks.
TSB #: 21-BR-002H
Page 15 of 19
SUBJECT:
BRAKE SERVICE BEST PRACTICE RECOMMENDATIONS
SUBJECT:
4.
Inspect the shoe lining for even wear and
thickness. Refer to the applicable vehicle
shop manual for service limits.
5.
Inspect the brake shoe springs. If any of the springs are broken, replace all brake shoe
springs.
During brake shoe replacement, it is also recommended to replace all shoe springs.
6.
Refer to the applicable vehicle shop manual
for locations regarding where to apply the
Copper Anti-Seize Brake Lube, P/N
00232-19086, to the contact/sliding points
between the shoes and brake components.
!
!
CAUTION
Prevent any grease from touching the
shoe lining or drum friction surfaces.
7.
To set the rear drum to shoe running clearance, refer to the applicable vehicle shop manual.
8.
Tighten all bolts to the torque specification recommended in the appropriate vehicle
shop manual.
TSB #: 21-BR-002H
Page 16 of 19
SUBJECT:
SUBJECT:
BRAKE SERVICE BEST PRACTICE RECOMMENDATIONS
Brake Fluid Service

Follow the applicable vehicle owner’s or shop manual for brake fluid inspection and replacement
intervals.
For more information on brake fluid service, refer to the applicable vehicle shop manual or TSBs.

!
!





1.
CAUTION
Do not reuse drained fluid.
Always use genuine DOT3 or DOT4 brake fluid as recommended in the applicable vehicle
shop manual. Using non-genuine DOT3 or DOT4 brake fluid can cause corrosion, and
can decrease the life of the system.
Verify dirt or other foreign matter does not contaminate the brake fluid.
Do not spill brake fluid onto the vehicle. This may lead to paint damage. If brake fluid
comes in contact with any paint surface, wash the surface off immediately with water.
When bleeding air, ensure that the fluid level never drops below halfway between MIN
and MAX in the reservoir.
Ensure that the brake fluid reservoir level
never drops below the halfway point
between MIN and MAX.
If the level drops below the halfway point, air
may be introduced into the system, and the
bleeding procedure must be restarted.
Ensure the fluid
level never drops
below halfway
between MIN and
MAX
NOTICE
Use genuine DOT 3 or DOT 4 brake
fluid as recommended in the applicable
vehicle shop manual
2.
Use a hose inserted into a partially filled
container of clean brake fluid to catch the old
brake fluid.
3.
Follow the brake bleeding sequence for the model and brake system type.
TSB #: 21-BR-002H
Page 17 of 19
SUBJECT:
BRAKE SERVICE BEST PRACTICE RECOMMENDATIONS
SUBJECT:
4.
After the bleeding procedure, ensure that the
caliper bleeding nipple is torqued to
specification.
Brake Bleeding Nipple Tightening Torque
5.
lb-ft
•5.1-9.4
kgf.m
•0.7-1.3
N.m
•6.9-12.7
Tighten all bolts to the torque specification recommended in the appropriate vehicle
shop manual.
Brake Caliper Fluid Inspection

If fluid appears around the brake caliper piston area, test the fluid to identify whether the fluid is
brake fluid, or assembly oil per the service procedures below.
1.
If oil/fluid is present on the brake caliper
piston area, test the fluid to determine if it is
brake fluid or assembly oil.
2.
Use a cotton swab to carefully collect a
sample of the fluid.
Do not disturb the caliper boot.
TSB #: 21-BR-002H
Page 18 of 19
SUBJECT:
SUBJECT:
3.
BRAKE SERVICE BEST PRACTICE RECOMMENDATIONS
Using an oil or water based ink pen, draw
several horizontal lines on a sheet of paper.
Wipe the collected fluid vertically down the
ink lines.
4.
If the ink does not smear, the fluid is not
brake fluid and is likely to be assembly oil.
 Wipe the excess oil using a clean
shop towel.
 Do not disturb the caliper boot.
If the ink runs/smears, the fluid is likely to be
brake fluid.
 Continue to investigate and repair the
source of the brake fluid.
Assembly oil
TSB #: 21-BR-002H
Brake fluid
Page 19 of 19
SUBJECT: