Kia Sephia Weak Brakes ~ Solved the Mystery! - Page 7 - Kia Forum

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post #61 of 70 (permalink) Old 05-05-2019, 02:26 PM Thread Starter
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The last Real Kia, came from its factory on march, 2004 and was a Kia Spectra with the 1.8L engine; then from April 2004 and on, all the Kias including the Spectra, are really rebadged Hyundais, with only differences on body / interior design; so the Newer Kia Spectras are really Hyundai Elantras with the 2.0L engines; (in the same way that the Kia Sorento / Hyundai Santa Fe are Brothers, the same goes to the Hyundai Tucson / Kia Sportage, also the Hyundai Sonata / Kia Optima, etc...), so, to find a first gen Kia Spectra with the "Upgraded from Factory" front disc Brakes in 10.1" fashion, was not easy; as almost all the "Newer" Spectras I came across on Junk Yards, were from the Hyundai plattform, and those are completely different animals with the Sephia, parts doesn't interchange at all.

But thanks to God, I found one 2004 Kia Spectra, built in late 2003 with the 1.8L engine
(Known as the "Old Body Style" somehow), which had the Famous Upgraded 10.1" front Disc Brakes.



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post #62 of 70 (permalink) Old 05-05-2019, 02:27 PM Thread Starter
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Lightbulb Important information !!!

Also I must mention that to do this Retrofitting, I need:

the Complete Hubs.
the Rotors.
the Calipers.
the Disc Pads.
along the Axles.

Because the "Upgraded from Factory" brakes, are completely different from the regular ones, the Axles on the upgraded ones are way much Beefier and also they are much thicker at the Hub's end, to the point that the axles from the Regular models doesn't touch the Splines inside the Hubs for the Upgraded brakes. However, the other end of the Axles
(the tripod joint that fits at the transmission's cups) is Equal, even the shafts has the same measurements and Splines, as long as you use parts from a donor car that has the same transmission as yours.

This Means that I needed a donor car that has Automatic Transmission as the "KiaStein" is, otherwise the Axles will not fit...

Think about it, it was not easy to find the Perfect donor car here, in Honduras; but Miracles happens.


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post #63 of 70 (permalink) Old 05-05-2019, 02:29 PM Thread Starter
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Arrow Finally, Photos (hoping that Photobucket allows me to share 'em Here)

This is the Donor Car, well... the front clip from an automatic 2004 model Kia Spectra premium, built in late 2003; which somehow came from the USA to the Local Junk Yard with only 31,000 Miles on the odometer:




The rim on the floor doesn't belong to it; the front clip already was empty, I mean without engine nor transmission; no interior parts, etc... and the front hubs were still with their 10.1" front Discs, Calipers, and Axles!




This is how I purchased them after I took 'em off from the Front Clip.


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post #64 of 70 (permalink) Old 05-05-2019, 02:30 PM Thread Starter
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The rotors had a superficial rust film, otherwise everything was immaculate; I cleansed everything and regreased all the ends of the Axles and Hubs; also changed the rubber boots that were torn and I was ready for the Upgraded Brakes' Retrofitting


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post #65 of 70 (permalink) Old 05-05-2019, 02:31 PM Thread Starter
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Talking

I removed off the Old Hubs still with everything attached,

Notice their small size and the holes all around the base for the wheel...





...Then I installed the New Hubs along everything.

Notice their increased size and no holes around their base.




Also, the bolts on the Upgraded Brakes' Calipers, are way much thicker and can be held with regular Nº 14 wrenches, while the smaller calipers on the old hubs, required Nº 7 hexagonal wrenches... among other improvements.


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post #66 of 70 (permalink) Old 05-05-2019, 02:33 PM Thread Starter
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Also, I had to Obtain new Brake Pads, which have nearly twice the rubbing area than the old ones; this new ones has almost the same rubbing area than a 2012 Sorento's Pads, little less, which is Big for a little sedan...




Some months ago, I painted all the four calipers and brake parts on the "KiaStein" with high temp, red enamel; so, as the rear calipers were Red, I had to paint this new front ones in same Red, to match the rear ones...



Then, after Bleeding completely the system three times in a cross-pattern, with the Help of my Wife; I took the "KiaStein" for a Test-Ride to the Mountains' Roads.


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post #67 of 70 (permalink) Old 05-05-2019, 02:34 PM Thread Starter
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Cool Thanks to God, everything is Successful !!!

SUCCESS!!!

I've never drove a vehicle with such braking power, using little pedal force to completely stop, in a straight line; no matter if the road is paved, gravel or unpaved road.

Finally, the KiaStein features the awesome Braking system that I always wanted, it doesn't lock the wheels easily, and lets you maneuver correctly, during panic braking.

And the Best part: my Wife is Happy with her car's Behaviour.
Thanks to God.

Kind Regards.


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post #68 of 70 (permalink) Old 05-05-2019, 02:41 PM Thread Starter
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So, this is the way to go: if you swap rear disc brakes on your second gen Sephia / first gen Spectra, those will be 10.1" so you Must swap the front disc brakes from the donor car also, in order to have same sized 10.1" front discs too, not the lousy 9" in front ... the Brakes works Awesomely with 10.1" all around in the four corners.

Don't touch the master cylinder at all.


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post #69 of 70 (permalink) Old 05-19-2019, 08:05 PM Thread Starter
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Arrow important notice

Even in this year (2019) the Lawsuit against Kia, from 2001 regarding this Defective Brakes, is not over... yet, you can read further information on the Subject, on the following web link:

~► https://www.carcomplaints.com/news/2...-lawsuit.shtml

Also, I saved a screenshot from the above linked web page, in case it disappears, see Below.

Kind Regards.
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post #70 of 70 (permalink) Old 05-19-2019, 08:28 PM Thread Starter
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Exclamation Disclaimer

The purpose of this thread is to help to the second gen Kia Sephia owners, to understand the reason why there were brake problems with this model, how they occurs and how to resolve them, in case you want to keep this car and drive it, safely.

Everything is explained in the first posts, then you can read about my efforts and how I completely solved all the issues, in an easy way, using alternative factory parts.

Disclaimer: Use ALL the information I share at your own risk, do not attempt to do any repair nor swap any part, if you do not have enough experience with this, nor enough mechanical skills. I am not suggesting nor recommending you to do what I did. Under no circumstances shall I be liable for any actions taken or omissions made from reliance on any information contained on any post that I've shared on any web forum and other media; nor shall I be liable for any other consequences from any misuse you might do with the information and photos that I share.

All graphics, images and photos I share online are my property and are free to share, as long as you preserve their watermark.

Always read this thread completely, in order to understand clearly everything.

Kind Regards and Blessings.

JesZeK


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