Tools You'll Need:
* Jack and jack stands: Absolutely essential for safety. Never work under a car supported only by a jack.
* Lug wrench: To remove the wheel.
* Wheel chocks: To prevent the car from rolling.
* Socket wrench set: You'll need sockets of various sizes, likely including a metric size for the caliper mounting bolts.
* C-clamp or caliper compression tool: To compress the caliper piston.
* Wrench or socket to remove caliper mounting bolts
* Hammer (optional): May be needed to gently tap the rotor off the hub.
* New rear rotor: Make sure you get the correct one for your Optima.
* Penetrating oil (like PB Blaster): To help loosen any stubborn bolts.
* Torque wrench: To tighten bolts to the manufacturer's specifications.
* Gloves and safety glasses: Protect yourself from dirt, grease, and potential injury.
* Repair Manual for a 2004 Kia Optima: This is crucial for specific torque specs and procedures.
Steps:
1. Safety First: Park on a level surface, engage the parking brake, and chock the front wheels. Raise the rear of the vehicle securely using the jack and place it on jack stands.
2. Remove the Wheel: Use the lug wrench to remove the wheel nuts and take off the wheel.
3. Remove the Caliper: Locate the caliper mounting bolts. Spray them with penetrating oil if necessary and let it sit for a few minutes. Use the appropriate socket wrench to carefully remove the bolts. Support the caliper with a bungee cord, wire, or hang it from something nearby to keep it from dangling by the brake line. Do not let the brake line hang freely.
4. Compress the Caliper Piston: Use the C-clamp or caliper compression tool to push the caliper piston back into the caliper housing. You'll need to do this to create enough space for the new rotor to fit. This may require some effort and the piston might need to be rotated as you compress it.
5. Remove the Old Rotor: The rotor may be held on by rust or corrosion. If it doesn't come off easily, gently tap the rotor around its edge with a rubber mallet or hammer (covered with a soft material to avoid damage) to break it free. It should slide off the wheel hub.
6. Install the New Rotor: Carefully slide the new rotor onto the wheel hub. It should fit snugly.
7. Reinstall the Caliper: Carefully put the caliper back onto the mounting brackets and replace the bolts, tightening them to the manufacturer's specified torque (found in your repair manual).
8. Reinstall the Wheel: Replace the wheel and tighten the lug nuts to the proper torque specification (again, consult your repair manual).
9. Lower the Vehicle: Carefully lower the vehicle from the jack stands.
10. Test the Brakes: Before driving, pump the brake pedal several times to ensure proper brake function. Test drive carefully and check for any unusual noises or vibrations.
Important Considerations:
* Brake fluid: If you're doing this yourself, make sure you top off your brake fluid reservoir. When you compress the caliper piston, you displace brake fluid.
* Lubrication: Lightly lubricate caliper pins and sliding surfaces with a caliper grease.
* Brake Pad Wear: Inspect your brake pads while you have the caliper off. If they're worn, replace them.
Remember, this is a general guide. Consult your 2004 Kia Optima's repair manual for detailed instructions and torque specifications. If you are unsure about any step, seek professional help from a qualified mechanic. Improper brake repair can be extremely dangerous.
