🔧 Kona - Rear Brake Pads & Rotor Replacement

You’ll remove the rear wheels, replace the rear brake pads and rotors, then reassemble and bed-in the pads. The key is handling the parking brake system correctly and torquing everything to spec so the brakes stay quiet and safe.

Difficulty Level: Intermediate | Estimated Time: 2-4 hours

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⚠️ Safety & Precautions

• ⚠️ Work on a flat, solid surface; never rely on a jack alone.
• ⚠️ Chock the front wheels before lifting the rear.
• ⚠️ Brake dust is unhealthy—use brake cleaner, not compressed air.
• ⚠️ Do not press the brake pedal with a caliper removed.
• ⚠️ If your Kona has an electronic parking brake (EPB), it must be put in service mode before pushing the pistons back.

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🔧 Required Tools

You'll need the following tools for this repair:

• Safety glasses
• Nitrile gloves
• Wheel chocks
• Floor jack (rated 3-ton minimum)
• Jack stands (rated 3-ton minimum)
• 21mm socket
• Breaker bar
• Ratchet
• 14mm socket
• 17mm socket
• Torque wrench (10–200 Nm range)
• Flathead screwdriver
• Bungee cord
• C-clamp brake piston compressor
• Disc brake piston wind-back tool (specialty)
• Scan tool with EPB service mode (specialty)
• Wire brush
• Rubber mallet

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Rear brake pad set - Qty: 1
• Rear brake rotors - Qty: 2
• Rear pad hardware/clip kit - Qty: 1
• Brake caliper slide pin grease (silicone) - Qty: 1
• Brake cleaner - Qty: 2 cans

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📋 Before You Begin

• Park on level ground and set the parking brake.
• Loosen the rear lug nuts slightly before lifting (use 21mm socket and breaker bar).
• Open the hood and check brake fluid level in the reservoir. If it’s near MAX, remove a small amount to prevent overflow when compressing pistons.
• If your Kona has an EPB switch (button), plan to retract the EPB with a scan tool with EPB service mode (specialty) before compressing pistons.
• Tip: Do one side at a time.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Lift and secure the rear

• Place wheel chocks in front of both front tires.
• Use a floor jack (rated 3-ton minimum) to lift the rear at the proper rear jacking point.
• Set the vehicle on jack stands (rated 3-ton minimum).
• Remove rear wheels using a 21mm socket and ratchet.

Step 2: If equipped, put the EPB into service mode

• If your Kona has an electronic parking brake switch, connect a scan tool with EPB service mode (specialty).
• Run the scan tool function to retract/release rear EPB for pad replacement (often shown as “EPB Maintenance Mode” or similar).
• Tip: Don’t skip this—EPB motors can be damaged.

Step 3: Remove the rear caliper

• Turn the steering wheel is not needed for rear; just position yourself for access.
• Remove the two caliper slide pin bolts using a 14mm socket and ratchet.
• Lift the caliper off the bracket.
• Hang the caliper from the suspension using a bungee cord (do not let it hang by the hose).
• Torque spec on install: Torque to 27 Nm (20 ft-lbs)

Step 4: Remove pads and caliper bracket

• Pull the pads out of the bracket (a flathead screwdriver can help gently).
• Remove the caliper bracket bolts using a 17mm socket and breaker bar.
• Remove the bracket and set it aside.
• Torque spec on install: Torque to 88 Nm (65 ft-lbs)

Step 5: Remove the rotor

• If the rotor is stuck, tap the rotor hat evenly with a rubber mallet to break it loose.
• Remove the rotor.
• Clean the hub face with a wire brush so the new rotor sits flat.

Step 6: Install the new rotor

• Spray off the protective oil from the new rotor using brake cleaner.
• Install the rotor onto the hub.
• Tip: A clean hub prevents brake pulsation.

Step 7: Prep the caliper bracket and install new pad hardware

• Clean the pad contact areas on the bracket with a wire brush.
• Install the new hardware/clips from the pad hardware kit.
• Apply a thin film of brake caliper slide pin grease (silicone) where the pad ears slide in the clips (avoid the pad friction surface).

Step 8: Compress the rear caliper piston

• If your Kona has EPB: use a C-clamp brake piston compressor to slowly push the piston straight back in.
• If your Kona has a cable-operated parking brake on the caliper: use a disc brake piston wind-back tool (specialty) to rotate-and-press the piston in (it turns while pushing).
• Watch the brake fluid reservoir while compressing; stop if it’s overflowing.

Step 9: Reinstall bracket, pads, and caliper

• Reinstall the caliper bracket using a 17mm socket and torque wrench. Torque to 88 Nm (65 ft-lbs)
• Install the new pads into the bracket.
• Reinstall the caliper over the pads.
• Install caliper slide pin bolts using a 14mm socket and torque wrench. Torque to 27 Nm (20 ft-lbs)

Step 10: Reinstall wheels

• Put the wheels back on and hand-start the lug nuts.
• Lower the vehicle off the stands using the floor jack (rated 3-ton minimum).
• Torque lug nuts in a star pattern using a torque wrench (10–200 Nm range). Torque to 118 Nm (87 ft-lbs)

Step 11: Exit EPB service mode (if used)

• Use the scan tool with EPB service mode (specialty) to command EPB back to normal mode.

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✅ After Repair

• Pump the brake pedal 10–15 times before moving the vehicle until the pedal feels firm.
• Check brake fluid level and top off only if needed.
• Verify the parking brake holds and releases normally.
• Test drive at low speed first and confirm no pulling or grinding noises.
• Bed-in the pads: make 6–10 moderate stops from 50 km/h to 10 km/h, letting brakes cool a bit between stops.

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💰 DIY vs Shop Cost

Shop Cost: ₹9,000-₹18,000 (parts + labor)

DIY Cost: ₹4,500-₹10,500 (parts only)

You Save: ₹4,500-₹7,500 by doing it yourself!

Shop labor rates vary but typically run ₹800-₹1500/hour. This repair takes a shop approximately 1.5-2.5 hours.

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🎯 Ready to get started?

HowToo makes it easy: same-day/2-day shipping on every part, plus all the tools and specialty tools you need! Check out the parts and tools sections below to add everything to your cart.