Parts You'll Need:
* Front brake rotors (2): Make sure these are the correct size and type for your Excel.
* Front brake pads (2 sets): Again, ensure these are the correct ones for your vehicle.
* Brake caliper grease: This is crucial for smooth caliper operation.
* New caliper bolts (if needed): Inspect the existing ones; if rusty or damaged, replace them.
* Wheel lug wrench: To remove and reinstall your wheels.
* Jack and jack stands: Essential for safe lifting of the vehicle.
* Wheel chocks: To prevent the car from rolling.
* Socket wrench set (metric): With the appropriate sizes for your brake system components.
* C-clamp or caliper compression tool: To compress the brake caliper piston.
* Wrench for caliper bracket bolts (if needed): This depends on your Excel's design.
* Wire brush: To clean surfaces before assembly.
* Brake cleaner: To clean brake parts thoroughly. Caution: Use in a well-ventilated area.
Steps (General - Refer to your repair manual for specifics):
1. Safety First: Park on a level surface, engage the parking brake, and chock the rear wheels. Use jack stands after lifting the car with a jack, never work under a car supported only by a jack.
2. Remove the Wheels: Loosen the lug nuts before jacking up the car. Remove the wheels.
3. Remove the Caliper: You may need to remove the caliper bracket bolts first (consult your repair manual). Then, using a C-clamp or caliper compression tool, carefully compress the brake caliper piston to create enough space for the new, thicker brake pads. Hang the caliper securely to avoid damaging the brake line.
4. Remove the Rotors: Once the caliper is removed, the rotors should slide off. If they're stuck, you might need to tap them gently with a rubber mallet. Clean the hub surface thoroughly.
5. Install the New Rotors: Slide the new rotors onto the wheel studs.
6. Install the New Brake Pads: Slide the new brake pads into the caliper assembly.
7. Reinstall the Caliper: Ensure the caliper slides smoothly and apply a small amount of brake caliper grease to the caliper pins. Reinstall the caliper and bracket bolts (with new bolts if needed) to the proper torque specification (from your repair manual).
8. Reinstall the Wheels: Tighten the lug nuts in a star pattern, then torque them to the manufacturer's specified torque (found in your repair manual).
9. Pump the Brakes: Pump the brake pedal several times to build pressure in the system and make sure the new brakes are working properly.
10. Test Drive: Carefully test drive your vehicle to ensure proper brake function.
Important Notes:
* Brake fluid: You may need to bleed the brakes after the repair, especially if the caliper was completely removed. This is best done with a friend to help. Refer to your repair manual for the proper bleeding procedure.
* Torque Specifications: Following the correct torque specifications for all bolts is crucial for safety and to prevent damage to your brakes.
* Repair Manual: A repair manual specific to your 1992 Hyundai Excel is highly recommended. It will provide detailed diagrams and instructions, ensuring you complete the job correctly and safely.
This is a simplified guide. Improper installation can lead to brake failure, resulting in serious injury or death. If you are not comfortable performing this repair yourself, take your vehicle to a qualified mechanic.
