How do you remove brake rotors from a 2001 Kia Optima?

Answer 1

First buy a Haynes or chiltons manual for your year model.This is a good reference to show illustrations of the components.I cannot keep this short with the general work to be done.I suggest loosening the lug nuts prior to jacking the car up.Next raise the car on one side.Then place a jack stand or concrete block to place under the car in a secure location.Once up and secure remove the wheel.Your rear disc brakes have what are called SET screws to secure the rotors to the hub.I recommend lubricating these with some liquid wrench and let sit briefly.These can be super tight and can strip out the head of the screw.I have had to heat these and even drill out and use a chisel to break free.At this point you will remove the slide pin bolts on the caliper 1 is on top and 1 is on the bottom.These should be a 12mm socket.Once the caliper is removed lay it to the side supported on the suspension OR use a bungee cord to keep the Brake line supported or from binding.Now your ready to remove the two(on the size it is either a 16 or 17 mm)socket bolts for the actual holding bracket.Once removed you can tap the rotor with a hammer left to right to break it free if stuck(this is normal).Reinstall install new rotor,I suggest using some permatex anti seize on the 2 Phillips head scews and install and tighten by hand.Next install the holding bracket and tighten the bolts and torque to 41 ft lbs with a torque wrench.Now your ready to do the actual caliper.You have two things to do.Make sure the rubber boots on the caliper are not torn or leaking grease as these may need to be replaced.Also Secondary you need to buy some permatex caliper grease for the slide pins.Coat lightly (VERY LIGHT) and reinstall in the caliper.Next is you have to have a caliper piston tool with a + sign (napa sells these for $12.00) and use's a 3/8 socket entension to go into it.You have to turn the piston clockwise to rotate the piston in until it is FLUSH.Then you can install the caliper over your New brake pad's as they are thicker and the piston has less distance to push the pads.Install the caliper and install the upper/lower slide pin bolts and torque to 17 ft lbs .Once the brake caliper is installed,install the wheel and tighten lug nuts to firm.Jack car up and lower to the point where the wheel touches ground but not completely lowered (so the wheel will not roll) .Then you want to use a torque wrench and torque the lugs to 85 ft lbs (technically Honda says 79) but I use 85 for my spouses 04 accord.I know my version seems complicated but,to do this correctly take's time a a good general mechanical know how.I just yesterday replaced a rear caliper,and both sides rotors,pads,grease slide pins and bleed the brake system in two hours.Cake for me reason I said buy a manual as this walks thru the steps 1-10 for example.I know I wrote a lot but this is as simple as I could make replacing rotors,as if your doing new rotors new pads and adjacent parts may need to be serviced and replaced in addition to the general work.

Answer 2

I have the same car (01 Optima Se V6). I am about to change the front rotors today, due to excessive warping. FYI, I went with factory pads - $60.00; and rotors from Kragen.com - $100 / pair. There are two tapped holes on the inner face of the rotor. The manual shows a two jaw- "double L" shaped threaded puller utilizing these holes along with the machined center on the end of the axle. The puller has its threaded rod screwing into (pushing against) the axle end, and thus pulls off the rotor.

I did not buy or rent such a puller. I'm going to see if I can simply work the rotor off with long bolts threaded through the holes in the rotor, hoping they bottom and then alternating about a quarter turn on each screw. If that doesn't work out I'll rent a puller.

Remember that the calipers should be supported (I use a bent metal coat hanger). Never let them hang by the rubber hydraulic hose.

This is a good time to flush the hydraulic system. Kia specs DOT3 fluid in the following order: LF, RR, RF, and Left Rear.

Good Luck! S. McDonald

Update: The rotors came off with just a bit of a tap with a dead blow hammer. A block of wood would have worked just as well. The swap was easy, no special tools or procedures. Why the manual shows a puller being used is beyond me.

The one thing I would do different next time is replacing the 4 pan head Phillips screws that keep the rotor snugged-up to the hub. (two per rotor, 4 total). They were pretty tight and I damaged them by using an old #3 Phillips screwdriver to remove them.

Cheers, S. McDonald

I had the same issue going on with a 2004 Kia Optima. The bolts I used were m8 with a 1.25 thread size. The length was 1.5" but once I dislodged the rotor, I tapped the face of the rotor and was able to work it free by hand. The length was just convenient as it kept me away from the tire bolts.

JTudela