This procedure covers removal and replacement of the front brake caliper on a 2016-2024 Hyundai Tucson with 2.5L I4 AWD, including bleeding the brake system.

Warnings

Tools required

Parts

• Front brake caliper assembly × 1 — Use OEM Hyundai or quality aftermarket for AWD model
• Copper crush washers for banjo bolt × 2 — Two washers per banjo bolt connection
• Caliper slide pin boots and hardware kit × 1 — If deteriorated or damaged

Fluids

• DOT 4 Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level, solid surface and engage parking brake firmly
2. Place wheel chocks behind rear wheels to prevent rolling
3. Do NOT press brake pedal once caliper is removed or piston will extend fully
4. Remove brake fluid reservoir cap and use turkey baster to remove approximately half the fluid to prevent overflow when compressing caliper piston
5. Loosen wheel lug nuts 1/4 turn while vehicle is on ground
6. Raise front of vehicle with floor jack at designated jacking point behind front wheel
7. Support vehicle on jack stands rated for vehicle weight, positioned at manufacturer frame points
8. Remove front wheel completely and set aside

Procedure

1. 1

   Inspect brake system and identify caliper type
   Visually inspect the caliper, brake hose, mounting hardware, and brake pads. Identify whether your caliper uses a flexible brake hose with banjo bolt or hard brake line connection. Most 2016-2024 Tucsons use banjo bolt connections at the caliper. Note condition of rubber slide pin boots for potential replacement.
2. 2

   Position drain container and disconnect brake hose
   Place drain container beneath caliper to catch brake fluid. Using a 17mm wrench, loosen and remove the banjo bolt connecting the flexible brake hose to the caliper. Brake fluid will drain out. Remove the banjo bolt completely and separate the hose from caliper. Immediately plug the open hose end with a clean rubber cap or wrap with plastic and tape to prevent fluid loss and contamination. Discard the old copper crush washers - do not reuse.
   ⚠Brake fluid will spray out under slight pressure. Keep face clear and have rags ready to catch fluid.
3. 3

   Remove caliper mounting bolts
   Locate the two caliper slide bolts on the rear side of the caliper assembly (facing the engine). These are typically 14mm or 17mm bolts depending on caliper design. Use the appropriate socket to remove both caliper mounting/slide bolts completely. Support the caliper by hand as you remove the second bolt to prevent it from falling.
   ⚠Caliper is heavy and will drop once second bolt is removed. Maintain control to avoid damaging brake rotor or suspension components.
4. 4

   Remove caliper from bracket
   Lift the caliper assembly straight up and off the brake rotor and caliper bracket. The brake pads may come with the caliper or remain in the bracket - note their orientation if replacing. Set the old caliper aside on a clean work surface. Do not allow it to hang by the brake hose if still attached.
5. 5

   Clean and inspect caliper bracket and hardware
   With caliper removed, inspect the caliper bracket (mounting bracket bolted to the knuckle) for wear, corrosion, or damage. Clean the brake pad slide areas on the bracket with brake cleaner and a wire brush. Inspect slide pin boots for tears or deterioration. If removing the bracket entirely, remove the two caliper bracket bolts using appropriate socket. This step is optional unless bracket is damaged or you are servicing additional components.
6. 6

   Prepare new caliper for installation
   Remove the new caliper from packaging. Verify it matches the old caliper design exactly. If the new caliper piston is not fully retracted, use a C-clamp or brake piston compression tool to slowly compress it fully inward. Apply a thin coat of high-temperature brake grease to the caliper slide pin shafts (not the boots). Ensure bleeder screw is closed (threaded in finger-tight).
7. 7

   Install new caliper onto bracket
   Position the brake pads into the caliper bracket slots if removed (inner and outer pads with anti-rattle clips in correct orientation). Carefully position the new caliper over the brake rotor and align the slide pin holes with the bracket mounting points. Slide the caliper into position ensuring pads are properly seated on both sides of the rotor.
8. 8

   Install and torque caliper mounting bolts
   Thread both caliper mounting bolts by hand to prevent cross-threading. Once both are hand-tight, use a torque wrench to tighten to specification. If your caliper uses slide-type bolts with rubber boots, these are typically 'Caliper Bolts' at 88 Nm. If using fixed mounting bolts, use 'Caliper Mounting Bolts' specification at 102 Nm. Verify which type your vehicle uses. Tighten in alternating pattern (one side, then other) to seat caliper evenly.
   ⚠️Incorrect caliper bolt torque can cause caliper to detach during braking, resulting in complete brake failure. Verify correct torque specification for your specific caliper design.
9. 9

   Connect brake hose with new crush washers
   Remove the plug or cap from the brake hose end. Position one NEW copper crush washer on each side of the hose banjo fitting. Align the banjo fitting with the caliper inlet port and thread the banjo bolt through by hand. Ensure both copper washers are properly seated. Using a torque wrench and 17mm socket, tighten the banjo bolt to specification.
   ⚠️ALWAYS use new copper crush washers. Reusing old washers will cause brake fluid leaks and potential brake failure. Verify washers are positioned on both sides of banjo fitting.
10. 10

    Bleed the brake caliper
    Attach clear plastic tubing to the bleeder screw and place the other end in a container with small amount of clean brake fluid. Have an assistant slowly press the brake pedal to the floor and hold. Open the bleeder screw 1/4 to 1/2 turn with an 8mm wrench. Fluid and air will flow through tubing. Close bleeder screw before assistant releases pedal. Repeat this process 5-8 times until only clear, bubble-free brake fluid flows. Monitor reservoir and maintain fluid level above MIN line throughout bleeding process.
    ⚠️Never allow brake fluid reservoir to run empty during bleeding or air will enter the master cylinder requiring complete system bleeding.
11. 11

    Torque bleeder screw
    Once bleeding is complete and only bubble-free fluid flows, close the bleeder screw while assistant maintains pedal pressure. Using a torque wrench, carefully tighten the bleeder screw to specification. These are easy to overtighten and strip.
    ⚠Bleeder screws are fragile. Do not exceed 10 Nm torque specification or the screw may strip, requiring caliper replacement.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
12. 12

    Reinstall wheel and lower vehicle
    Clean the wheel hub face and inspect for damage. Mount the wheel onto the hub and thread all lug nuts by hand. Tighten lug nuts in a star pattern with wrench until snug but not fully torqued. Lower vehicle from jack stands until tire just contacts ground with slight weight. Using torque wrench, tighten lug nuts to specification in star pattern. Fully lower vehicle and remove jack and stands.

Reassembly

1. Fill brake fluid reservoir to MAX line with new DOT 4 brake fluid from sealed container
2. Install reservoir cap securely to prevent moisture contamination
3. If both front calipers were replaced, bleed opposite side using same procedure
4. Remove wheel chocks from rear wheels
5. Pump brake pedal 15-20 times with engine off until firm pedal feel is achieved
6. Check brake fluid level again and top off if needed - fluid level will drop as system fills

Verification

• With engine off, pump brake pedal firmly several times - pedal should become firm and hold steady pressure without sinking
• Inspect all connection points (banjo bolt, bleeder screw, caliper bolts) for any signs of brake fluid leakage
• Start engine and verify brake warning light is off on instrument cluster
• With vehicle still in park, press brake pedal firmly - pedal should feel solid with no excessive travel or sponginess
• Test drive vehicle in safe area at low speed (under 15 mph) and verify brakes engage smoothly without pulling to one side
• After test drive, re-inspect all connections for leaks while system is at operating pressure
• After 50-100 miles, re-torque wheel lug nuts to specification and inspect brake fluid level
• Bedding-in new caliper: perform 8-10 moderate stops from 40 mph to properly seat brake pads, allowing 30 seconds between stops to prevent overheating

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