This procedure covers replacement of a single rear brake rotor on a 2016-2024 Hyundai Tucson with the 2.5L I4 AWD engine, including caliper removal, rotor replacement, and proper torque specifications.

Warnings

Tools required

Parts

• Rear brake rotor × 1 — Use OEM specification or equivalent quality aftermarket
• Rotor set screw (if damaged) × 1 — M6 x 1.0 x 10mm Phillips screw

Fluids

• DOT 4 Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level, solid ground and engage parking brake firmly
2. Loosen rear wheel lug nuts 1/4 turn while vehicle is on ground (do not remove)
3. Lift rear of vehicle with floor jack at designated lift point near rear wheel being serviced
4. Support vehicle securely on jack stands placed at manufacturer-designated jack points
5. Remove wheel lug nuts completely and remove wheel
6. Clean area around caliper and rotor with brake cleaner to prevent contamination
7. Verify you have all tools and the correct replacement rotor before beginning disassembly

Procedure

1. 1

   Inspect brake system condition
   Visually inspect the brake caliper, brake lines, and pad wear. Check for any leaks, damaged rubber boots on slide pins, or unusual wear patterns. If any abnormalities are found, address them before proceeding. Verify that the replacement rotor matches the original in diameter, thickness, and mounting pattern.
2. 2

   Remove caliper slide pin bolts
   Locate the two caliper slide pin bolts on the rear of the caliper assembly (accessed from behind). Use a 17mm socket or wrench to remove both slide pin bolts. Keep these bolts together as they will be reused. The caliper should now be free to pivot or lift away from the rotor.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
3. 3

   Remove and support caliper
   Carefully lift the caliper off the rotor and caliper bracket. Do NOT disconnect the brake hose. Use wire, a bungee cord, or suspend from a nearby suspension component to support the caliper weight. Ensure there is no tension or stress on the brake hose. Position the caliper so it is secure and will not fall.
   ⚠️Never let the caliper hang by the brake hose. Damage to the hose can cause catastrophic brake failure.
4. 4

   Compress caliper piston
   Before removing the rotor, use a C-clamp or brake caliper piston tool to slowly compress the caliper piston back into its bore. Place the clamp on the back of the caliper body and against the outer brake pad. This step makes reassembly easier and prevents brake fluid overflow. Monitor the brake fluid reservoir and remove fluid if necessary to prevent overflow.
   ⚠Compressing the piston forces brake fluid back into the master cylinder reservoir. Check reservoir level and remove excess fluid with a turkey baster or syringe to prevent overflow and paint damage.
5. 5

   Remove rotor set screw
   Locate the Phillips head set screw on the face of the rotor (if present). Use a Phillips screwdriver to remove this screw. If the screw is corroded or stripped, use an impact driver or carefully drill it out. This screw is only for assembly retention and does not need to be replaced if damaged.
   Torque spec

   Rotor Set Screws7 Nm (5 lb-ft)
6. 6

   Remove old brake rotor
   Pull the rotor straight off the wheel hub. If the rotor is stuck due to rust or corrosion, tap it gently from behind with a rubber mallet, alternating sides. Do not use excessive force. If severely seized, spray penetrating oil around the hub center and wait 15 minutes before attempting again. On AWD models, ensure the parking brake is released.
7. 7

   Clean hub mounting surface
   Use a wire brush to thoroughly clean the hub face where the rotor mounts. Remove all rust, scale, and debris. Clean the hub center bore as well. Any buildup here will cause rotor runout and brake pulsation. Spray with brake cleaner and wipe dry with a clean cloth.
8. 8

   Prepare and install new rotor
   Remove any protective coating from the new rotor with brake cleaner (new rotors are shipped with an anti-corrosion coating). Clean both sides thoroughly. Apply a thin coat of anti-seize compound to the hub face (not the rotor friction surfaces). Slide the new rotor onto the hub, aligning any holes with the hub studs.
   ⚠Do not get anti-seize, grease, or oil on the rotor friction surfaces. Contamination will cause brake failure and require rotor replacement.
9. 9

   Install rotor set screw
   If using the set screw, thread it into the rotor face by hand first, then tighten to specification using a Phillips screwdriver. Do not overtighten as these screws strip easily. This screw only holds the rotor during assembly; the wheel and lug nuts provide clamping force during operation.
   Torque spec

   Rotor Set Screws7 Nm (5 lb-ft)
10. 10

    Reinstall brake caliper
    Remove the caliper from its supported position. Verify the caliper piston is fully compressed. Position the caliper over the new rotor and align the slide pin bolt holes with the caliper bracket. If the caliper doesn't fit, the piston needs further compression.
    ℹ️Ensure brake pads are properly seated in the caliper bracket before reinstalling the caliper.
11. 11

    Install and torque caliper slide pin bolts
    Apply a thin coat of silicone brake grease to the slide pin bolt threads and smooth shaft (not the threaded portion that enters the bracket). Thread both slide pin bolts in by hand to prevent cross-threading. Using a torque wrench and 17mm socket, torque both caliper slide pin bolts to 35.0 Nm (26 lb-ft) in a crisscross pattern.
    ⚠️CRITICAL TORQUE SPECIFICATION: Improperly torqued caliper bolts can cause caliper detachment and complete brake failure. Verify torque wrench calibration and use exact specification.
    Torque spec

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)
12. 12

    Reinstall wheel
    Place the wheel back onto the hub, aligning the holes with the studs. Thread all lug nuts on by hand to prevent cross-threading. Snug them in a star pattern with the lug wrench, but do not fully tighten yet.
13. 13

    Lower vehicle and torque lug nuts
    Remove jack stands and carefully lower the vehicle until the tire just touches the ground with slight weight on it. Using a torque wrench, tighten the wheel lug nuts to 140.0 Nm (103 lb-ft) in a star pattern. Fully lower the vehicle and remove the jack.
    ⚠️CRITICAL: Wheel lug nuts must be torqued in a star pattern to specification. Improper torque can cause wheel detachment.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. If both rear rotors were replaced, repeat all steps for the opposite side
2. Check brake fluid level in master cylinder reservoir and top off to MAX line with DOT 4 brake fluid if needed
3. Do not mix different types or brands of brake fluid

Verification

• Before driving, pump the brake pedal several times until it feels firm and reaches normal height. The pedal may be soft initially due to piston compression.
• Check brake fluid level one final time and verify no leaks around caliper or brake lines
• Test brakes at low speed (under 5 mph) in a safe area to verify proper operation before normal driving
• Perform 15-20 moderate stops from 30-40 mph to properly bed in the new rotor and transfer pad material to the rotor surface
• Avoid hard braking for the first 200 miles to allow proper break-in
• Listen for any unusual noises and monitor for vibration or pulling during braking. Any abnormalities require immediate inspection
• After 50-100 miles, recheck wheel lug nut torque to 140 Nm (103 lb-ft)
• If brake pedal feels soft or spongy after service, the system may have air in it and require bleeding by a professional

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