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

Warnings

Tools required

Parts

• Rear brake caliper assembly × 1 — Use OEM specification
• Copper crush washers for banjo bolt × 2 — Use OEM specification
• Caliper mounting hardware kit (if deteriorated) × 1 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level ground and engage parking brake firmly
2. Loosen rear wheel lug nuts 1/4 turn while vehicle is on ground
3. Raise rear of vehicle with floor jack and support securely on jack stands rated for vehicle weight
4. Remove rear wheel completely
5. Locate brake fluid reservoir under hood and remove cap (place clean rag over opening to prevent contamination)
6. Have catch pan ready to collect brake fluid spillage

Procedure

1. 1

   Clean brake caliper area
   Spray brake cleaner on the caliper, mounting bolts, and brake line connection to remove dirt and corrosion. Allow to dry. This prevents contamination of the brake system during disassembly.
2. 2

   Disconnect brake line from caliper
   Place catch pan under caliper. Using a 10mm flare nut wrench, loosen and remove the banjo bolt securing the brake hose to the caliper. Immediately plug the brake line with a clean rubber cap or wrap in plastic to prevent fluid loss and contamination. Discard the old copper crush washers - do not reuse.
   ⚠Brake fluid will drain from the line. Keep away from painted surfaces and catch all fluid.
3. 3

   Remove caliper mounting bolts
   Locate the two caliper mounting bolts (typically 17mm) on the rear of the caliper assembly. These may be accessed from behind the caliper bracket. Remove both bolts completely and retain for inspection.
   ℹ️Some Tucson models use caliper bolts while others use caliper mounting bolts - verify which type your vehicle has before proceeding.
4. 4

   Remove old caliper
   Lift the caliper assembly off the brake rotor and bracket. Inspect the brake pads and rotor for wear - if replacing the caliper due to seizure, consider replacing pads and inspecting rotor condition as well. Remove caliper completely from vehicle.
5. 5

   Inspect caliper bracket and hardware
   Examine the caliper bracket for damage, corrosion, or worn slide pins. Clean the bracket mounting surface with brake cleaner. If slide pins are corroded or damaged, replace the hardware kit. Apply a thin coat of high-temperature brake grease to slide pins if reusing.
6. 6

   Prepare new caliper
   Remove the new caliper from packaging. Verify bleeder screw is present and closed. If the caliper piston is fully extended, compress it using a C-clamp or brake piston tool to allow clearance over the brake pads and rotor. Ensure dust boot is properly seated.
7. 7

   Install new caliper
   Position the new caliper over the brake rotor and align with mounting holes on the bracket. Ensure brake pads are properly positioned if they were removed. Thread in both caliper mounting bolts by hand first to ensure proper thread engagement.
8. 8

   Torque caliper bolts
   Using a torque wrench, tighten the caliper mounting bolts to the specified torque. If your vehicle uses the standard caliper bolts, torque to 88 Nm (65 lb-ft). If your vehicle uses the larger caliper mounting bolts, torque to 102 Nm (75 lb-ft). Verify which type is correct for your specific Tucson model year.
   ⚠️Improperly torqued caliper bolts can cause caliper detachment and complete brake failure. Verify correct specification for your vehicle.
9. 9

   Connect brake line
   Install NEW copper crush washers on both sides of the banjo fitting (one on each side of the caliper mounting ear). Position the brake hose banjo bolt and thread by hand. Ensure the hose is not twisted or kinked.
   ⚠️Always use new copper washers. Reusing old washers can cause brake fluid leaks and brake failure.
10. 10

    Torque brake line banjo bolt
    Using a torque wrench, tighten the brake hose banjo bolt to 41 Nm (30 lb-ft). Do not overtighten as this can damage the fitting or caliper. Verify there is no visible leakage around the connection.
    ⚠️Verify you are using the correct torque specification - brake hose banjo bolt (41 Nm) vs brake line banjo bolt (25 Nm) specifications differ.
11. 11

    Bleed rear brake caliper
    Attach clear tubing to the bleeder screw and submerge the other end in a container with clean DOT 4 brake fluid. Have an assistant slowly pump the brake pedal 3-4 times and hold pressure. Open the bleeder screw 1/4 turn to release fluid and air. Close bleeder before pedal reaches floor. Repeat until no air bubbles appear in tubing. Top off brake fluid reservoir as needed during bleeding process.
    ⚠Never allow brake fluid reservoir to run empty during bleeding or air will enter the ABS system requiring professional scan tool bleeding.
12. 12

    Torque bleeder screw
    Once bleeding is complete and only clear fluid with no bubbles flows from the bleeder, tighten the bleeder screw to 10 Nm (7 lb-ft). Do not overtighten as bleeder screws are easily stripped.
    ⚠Bleeder screws are fragile. Overtightening will strip threads and require caliper replacement.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
13. 13

    Reinstall wheel
    Clean wheel mounting surface on hub. Position wheel onto hub and thread all lug nuts by hand. Tighten lug nuts in a star pattern until snug but do not fully torque yet.
14. 14

    Lower vehicle and final torque
    Lower vehicle from jack stands until tire just contacts ground (tire should support weight but vehicle should still be slightly raised). Torque wheel lug nuts to 136 Nm (100 lb-ft) in a star pattern. Fully lower vehicle and remove jack. Repeat entire procedure for opposite side if replacing both calipers.
15. 15

    Final brake system check
    Check brake fluid reservoir level and top off to MAX line with fresh DOT 4 fluid. Reinstall reservoir cap. Pump brake pedal slowly 10-15 times until firm pedal is achieved. Check all connections for leaks. Inspect under vehicle for any fluid drips at caliper or brake line connections.
    ⚠️Do not drive vehicle until a firm brake pedal is achieved. If pedal remains soft after multiple pumps, air remains in system or there is a leak.

Reassembly

1. Ensure brake fluid reservoir is filled to MAX line with fresh DOT 4 fluid
2. Verify all bleeder screws are tight and not leaking
3. Confirm all brake line connections are secure with no visible fluid seepage
4. Double-check that wheel lug nuts are torqued to specification

Verification

• Start engine and pump brake pedal - pedal should be firm and not sink to floor
• Check brake warning light on dashboard - it should not be illuminated
• Perform a low-speed brake test in a safe area (parking lot) to verify proper braking function
• Verify no pulling to one side during braking
• After test drive, recheck all connections for leaks while warm
• Check brake fluid level after test drive and top off if needed
• Listen for any unusual noises from rear brakes during light brake application
• After 50-100 miles of driving, re-torque wheel lug nuts and inspect caliper area for any seepage

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