Hyundai i20 Rear Brake Maintenance Guide

Hyundai i20 Rear Disc Brake and Handbrake Shoe Maintenance

Many modern vehicles, including the 2012 Hyundai i20 sold in the UK, utilise a clever design where the rear disc brake assembly also houses the mechanism for the handbrake. This often involves small, secondary brake shoes located within the hub of the brake disc itself. While seemingly complex, understanding and maintaining these components can prevent issues like binding brakes, reduced handbrake effectiveness, and premature wear. This guide aims to provide a clear, step-by-step approach to inspecting and maintaining these vital parts, drawing on practical experience to help you tackle the job with confidence.

Understanding the System

The rear braking system on your 2012 i20 typically consists of a disc rotor, with a caliper that houses the main brake pads for service braking. Encased within the centre of this disc rotor is a smaller drum-like arrangement that holds the handbrake shoes. When you engage the handbrake, these shoes expand outwards, pressing against the inner surface of the disc rotor to hold the vehicle stationary. This dual-purpose design is common, but it means that the handbrake shoes can be affected by the same elements that might impact your main brakes, and also by disuse.

Common Issues and Symptoms

Several symptoms might indicate a need to inspect your rear brake components:

• Handbrake Not Holding Firmly: If your handbrake doesn't hold the car securely on a slight incline, the shoes may be worn, misadjusted, or contaminated.
• Binding Handbrake: You might notice a slight drag or feel the handbrake is 'on' even when released. This can be due to seized adjusters, contaminated shoes, or improperly retracting shoes.
• Uneven Braking: While less common for the handbrake shoes themselves, general brake imbalance could point to issues within the rear caliper or disc assembly.
• Noise: A grinding or scraping noise when the handbrake is applied or released can indicate worn shoes or a problem with the adjuster mechanism.

Step-by-Step Maintenance Guide

Here’s a breakdown of the maintenance process, assuming you have some basic mechanical knowledge and the necessary tools.

1. Accessing the Caliper and Pads

To begin, you'll need to remove the road wheel. Then, locate the brake caliper. The caliper itself is usually held in place by two bolts, often referred to as 'set screws' or guide bolts. These are typically 14mm bolts. Removing these will allow you to pivot or remove the caliper to access the brake pads.

Important Note: Some caliper designs require the removal of slider pins, which are often covered by rubber boots. Ensure these pins are clean and lubricated. Siezed slider pins (as noted in the provided information) are a common issue and can lead to uneven pad wear and binding.

Tip: For the Hyundai i20, the piston in the caliper can often be pushed back with just your thumb. If it’s stiff, a C-clamp or a dedicated brake piston tool can be used. Be careful not to damage the dust seal.

2. Checking Slider Pins

The slider pins are crucial for allowing the caliper to move freely as the pads wear. If these pins seize, the caliper can become 'stuck', leading to the brake pads constantly dragging on the disc. As highlighted in the user notes, these pins are often secured by the same 14mm set screws mentioned earlier. If they are seized, you might need to use penetrating oil (like WD-40), a spanner (possibly 16mm or 17mm), and gentle persuasion with a hammer and a sturdy screwdriver to free them. Once removed, clean them thoroughly with emery cloth, apply a suitable high-temperature grease, and reinstall them.

3. Inspecting and Cleaning Handbrake Shoes

This is the core of maintaining the handbrake function. Even if you haven't noticed any issues, it's good practice to remove the disc rotor (often called a drum or hub in this context) to clean out the handbrake shoes. This prevents the build-up of dust and rust, which can cause the shoes to stick.

• Remove Caliper Frame: First, remove the bracket that holds the brake caliper. This is usually attached with larger bolts (often 14mm), separate from the slider pin bolts.
• Removing the Disc Rotor: This can sometimes be tricky, especially if there's a bit of rust around the hub. The disc rotor needs to be pulled off the wheel studs. If it's stuck, a rubber mallet or a wheel puller might be necessary.
• Accessing the Adjuster: Inside the hub, you'll see the handbrake shoes and an adjuster mechanism. On the Hyundai i20, there's often a rubber bung or plug on the disc rotor itself. Removing this plug provides access to the adjuster.
• Adjusting the Shoes: The adjuster is typically a toothed wheel. You'll need to turn this to retract the shoes, making it easier to remove the disc rotor. Determining the correct direction to turn can be trial and error – if one way doesn't work, try the other. The goal is to slacken the shoes so they don't bind on the rotor.

Table: Adjuster Operation

Note: The exact direction may vary based on the adjuster design and viewing angle. It's best to experiment gently.

4. Lubricating the Adjuster

Seized adjusters are a common problem, especially if the car isn't used regularly. If you can see the end of the adjuster through the hole in the disc rotor, try applying some lubricant. Ideally, once the disc rotor is removed, the adjuster should turn freely by hand. If it's stiff, lubricate it and allow it time to penetrate. Cleaning the shoes and the contact points on the hub is also beneficial.

5. Adjusting Handbrake Cables

The handbrake cable tension is also critical. Over time, cables can stretch, leading to a loss of handbrake effectiveness. Adjustment is usually done via a mechanism accessible from within the car's cabin.

• Accessing the Adjustment Point: You'll typically need to remove the bottom part of the rear of the centre console. This usually involves a 10mm bolt located quite far down. Using a long extension bar and perhaps some Blu-Tack on the socket can help prevent losing the bolt.
• Making the Adjustment: Once the console is lifted or removed (sometimes a plastic container can be used to prop it up), you should find an adjustment nut or lever. This is often adjusted with a 12mm spanner. The goal is to remove slack from the handbrake cable so that when the lever is in its lowest effective position (e.g., 2-3 clicks from fully down), the handbrake is engaged, but when fully released, there is no drag on the rear wheels.

When to Replace Handbrake Shoes

A common misconception is that a small amount of lining material means the shoes need immediate replacement. For handbrake shoes, this is often not the case. As they are only used for parking and occasional gentle application, they wear very slowly. Even with only a couple of millimetres (roughly 1/16" to 3/32") of lining material remaining, they can still have a considerable amount of life left. New shoes often have less than 3mm of lining. Unless they are physically damaged, contaminated with oil, or severely worn, they may not require replacement as frequently as you might think.

Note: Replacing the handbrake shoes themselves can be more involved. In some cases, it may be necessary to remove the entire hub assembly to gain proper access to the springs and retaining clips that hold the shoes in place.

Frequently Asked Questions (FAQs)

Q1: My handbrake feels loose. What should I check first?
Check the handbrake cable adjustment inside the car's centre console. If that seems correct, inspect the handbrake shoes and adjuster mechanism within the rear disc rotors for contamination or seized adjusters.

Q2: Can I drive with binding rear brakes?
Driving with binding brakes is not recommended. It will lead to premature wear of brake pads, discs, and potentially the handbrake shoes, as well as reduced fuel efficiency and potentially overheating of the braking system.

Q3: How often should I clean the handbrake shoes?
It's a good idea to inspect and clean them during regular brake servicing, perhaps every 12-24 months, or if you notice any issues with the handbrake performance. Cars that are used infrequently are more prone to issues with seized components.

Q4: Do I need special tools to maintain these brakes?
While some specialist tools can help, the basic maintenance described here can often be done with a standard socket set, wrenches, screwdrivers, pliers, and potentially a C-clamp or brake piston tool. A torque wrench is recommended for reassembling caliper bolts to the manufacturer's specifications.

Conclusion

Maintaining the handbrake system within your Hyundai i20's rear disc brakes is an essential part of ensuring your vehicle's safety and reliability. By following these steps, you can address common issues, prevent future problems, and keep your handbrake working effectively. Regular inspection and cleaning of the handbrake shoes and adjuster mechanism, along with correct cable tension, will contribute to a longer lifespan for your braking components.

If you want to read more articles similar to Hyundai i20 Rear Brake Maintenance Guide, you can visit the Maintenance category.