Hyundai i40 rear brakes – Technical instructions from Blue Print

The i40 uses an electromechanical parking brake system similar to the solutions used by Volkswagen, Renault, Volvo, Ford and BMW.
Below is the procedure for replacing the rear brake pads and discs:

Check the brake system by checking the level and condition of the brake fluid, possible leaks and the operation of the main and parking brakes.

Note: Due to the fact that the actuators of the actuated parking brake consume a lot of current (c. 14-20 amps), it is recommended to turn on a backup device for voltage in the electrical system. If ignition is included, connect a tester to the 16-pin diagnostic socket, then check all possible errors in the electrical system of the parking brake and the ABS system.

After lifting the vehicle, remove the rear wheels and check the brake hoses, wiring, and driven brake drive, as well as the rear brake pads and discs. The minimum thickness of the discs is 8.4 mm and the thickness of the brake pads is 2.0 mm.
Using a suitable diagnostic tester, return the actuator to the electric parking brake to a service position.

Remove the two Imbus screws 12 mm from the brake apparatus and then carefully remove and move the apparatus aside without overloading the brake hose and wiring the drive mechanism.
No need to screw the piston – just press it inward.

Remove the old brake pads and fixing springs.
To dismantle the brake bracket (A), first unscrew the bolt of the suspension element (B). This will allow you to unscrew the two bolts of the brake bracket (C).

Develop the mounting bolts on the rear brake disc and dismantle it. Clean the contact surfaces and degrease the new brake disc, if necessary, before installation.

Install the brake bracket bolts, the suspension element bolt and then install the new brake pads and mounting springs – then the brake machine can be installed.

Finally, connect the electric actuators of the parking brake and check the operation of the main and parking brake. The check should also include possible brake fluid leaks. Then check for malfunction codes in the parking brake system and the ABS system, then mount the wheels by tightening them with a torque of 88-108 Nm and making trial driving.