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

Warnings

Tools required

Parts

• Brake caliper bracket (specify front or rear, left or right) × 1 — Use OEM specification
• Brake pads (if worn or damaged) × 1 — Use OEM specification
• Brake hardware kit (anti-rattle clips, shims) × 1 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level, solid ground. Place transmission in Park (automatic) or first gear (manual). Apply parking brake firmly.
2. Remove approximately 1/3 of brake fluid from master cylinder reservoir using turkey baster or transfer pump to prevent overflow when compressing caliper pistons. Dispose of old fluid properly.
3. Loosen wheel lug nuts 1/4 turn while vehicle is still on ground.
4. Lift vehicle using floor jack at designated jacking point and secure with jack stands rated for vehicle weight.
5. Remove wheel completely and set aside.
6. Spray brake assembly with brake cleaner and allow to dry. Inspect brake components for damage, excessive wear, or fluid leaks.

Procedure

1. 1

   Remove brake caliper
   Locate the two caliper slide pin bolts on the back of the caliper assembly. Using appropriate socket (typically 17mm), remove both caliper slide pin bolts. Carefully lift the caliper off the bracket and rotor. Support the caliper with wire or bungee cord attached to the suspension or chassis—never let it hang by the brake hose.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
2. 2

   Remove brake pads and hardware
   With caliper removed, slide the brake pads out of the caliper bracket. Remove all anti-rattle clips, shims, and spring hardware from the bracket. Note the orientation and position of all hardware for reassembly. Inspect pads for wear; if less than 3mm thickness remains or if replacing the bracket, install new pads during reassembly.
3. 3

   Remove caliper bracket
   Locate the two caliper bracket bolts securing the bracket to the steering knuckle (front) or axle carrier (rear). These are larger bolts typically requiring 19mm socket. Using a breaker bar if necessary, remove both caliper bracket bolts. The bracket should now lift free from the rotor and mounting surface. If stuck, tap gently with plastic mallet.
   ⚠Caliper bracket bolts are high-torque fasteners. Use a breaker bar and ensure proper socket engagement to avoid rounding bolt heads.
   Torque spec

   Caliper Bracket Bolts - Front120 Nm (88 lb-ft)
4. 4

   Clean mounting surfaces
   Using a wire brush, thoroughly clean the caliper bracket mounting surfaces on the knuckle or axle carrier. Remove all rust, corrosion, and debris. Clean the bracket bolt holes and threads. Inspect mounting surface for damage or cracks. Clean the caliper slide pin bores in the old or new bracket if reusing slide pins.
5. 5

   Prepare and install new caliper bracket
   If installing a new bracket, transfer any necessary components from the old bracket if not included with new part. Apply medium-strength thread locker to the caliper bracket bolt threads as recommended. Position the new bracket over the rotor and align with mounting holes on the knuckle or carrier. Start both bracket bolts by hand to ensure proper thread engagement.
   ℹ️Ensure the bracket is oriented correctly with slide pin bores positioned to accept the caliper.
6. 6

   Torque caliper bracket bolts
   Using a torque wrench, tighten the caliper bracket bolts to specification in a cross pattern (alternating between bolts). For front brackets, torque to 120 Nm (88 lb-ft). Verify both bolts are properly seated and torqued. Double-check torque on both bolts after initial tightening.
   ⚠️Proper torque on bracket bolts is critical for safe brake operation. Under-torquing can cause bracket loosening and catastrophic brake failure. Use a calibrated torque wrench.
   Torque spec

   Caliper Bracket Bolts - Front120 Nm (88 lb-ft)
7. 7

   Install brake hardware and pads
   Install new anti-rattle clips and hardware into the caliper bracket according to their original orientation. Ensure all clips are fully seated. Apply a thin layer of silicone brake grease to pad backing plate contact points (not friction surface). Install inner and outer brake pads into the bracket, ensuring they are properly seated in the hardware clips.
8. 8

   Prepare and lubricate caliper slide pins
   Remove caliper slide pins from the old bracket if reusing, or inspect pins that came with the new bracket. Clean slide pins thoroughly with brake cleaner. Inspect slide pin boots for tears or damage; replace if compromised. Apply silicone brake grease generously to the slide pin shaft (not the threaded portion). Ensure slide pins move freely in the bracket bores.
   ⚠Do not use petroleum-based grease on brake components. Use only silicone brake grease or grease specified for brake applications.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
9. 9

   Compress caliper piston
   Before installing the caliper over new pads, the piston must be compressed fully into the caliper bore. Use a C-clamp or brake caliper piston tool positioned against the piston and back of the caliper body. Slowly compress the piston completely flush with or slightly recessed into the bore. Monitor the brake fluid reservoir to ensure it does not overflow.
   ⚠Compressing the piston forces brake fluid back into the master cylinder reservoir. This is why fluid was removed during preparation.
10. 10

    Install caliper and torque slide pin bolts
    Remove the wire or bungee cord supporting the caliper. Carefully position the caliper over the brake pads and bracket, ensuring the brake hose is not twisted or kinked. Align the slide pin bolt holes. Insert both slide pin bolts and thread by hand initially. Using a torque wrench, tighten caliper slide pin bolts to 35 Nm (26 lb-ft). Verify caliper moves freely on slide pins without binding.
    ⚠️Ensure slide pin bolts fully engage threads in the bracket. Cross-threading will cause bolt failure and caliper detachment.
    Torque spec

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)
11. 11

    Reinstall wheel and torque lug nuts
    Position the wheel onto the hub, aligning lug nut holes. Install all lug nuts and tighten by hand. Using a torque wrench, tighten lug nuts to 140 Nm (103 lb-ft) in a star pattern (opposite sides alternating). Lower the vehicle from jack stands to the ground, then verify final lug nut torque in star pattern with vehicle weight on wheels.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. If brake work was performed on both sides of the axle, verify all components are properly installed and torqued on both sides.
2. Check brake fluid level in master cylinder reservoir. Top off with fresh DOT 4 brake fluid to the MAX line. Do not overfill.
3. Before starting the engine or moving the vehicle, pump the brake pedal slowly 10-15 times until firm resistance is felt. The pedal should feel firm and consistent.
4. If the brake pedal feels spongy or goes to the floor, do not drive the vehicle. The system may require bleeding. Seek professional service if unfamiliar with brake bleeding procedures.

Verification

• With vehicle still elevated or on level ground, verify all caliper bracket bolts, slide pin bolts, and wheel lug nuts are torqued to specification.
• Visually inspect for any brake fluid leaks around caliper, hoses, and fittings.
• With engine running (to activate brake booster), apply firm pressure to brake pedal. Pedal should feel firm and not slowly sink. If pedal sinks, there is air in the system or a leak—do not drive.
• Perform a low-speed test drive in a safe area. At 5-10 mph, apply brakes firmly. Vehicle should stop smoothly without pulling to one side. Brake pedal should remain firm.
• After test drive, check for vibrations, noises, or pulling while braking. Re-check all torque specifications and inspect for leaks.
• Perform several moderate brake applications from 30-40 mph to properly seat the new pads (if replaced). Avoid hard braking for the first 200 miles to allow proper pad bedding.

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