Brake Hose - Rear

Replace the rear brake hose on a 2016-2024 Hyundai Tucson 2.5L AWD, including bleeding the brake system to restore proper hydraulic function.

Warnings

Tools required

Parts

• Rear brake hose × 1 — Use OEM specification for 2016-2024 Tucson
• Copper crush washers for banjo bolt × 2 — Two washers per banjo bolt connection
• Brake hose retaining clip (if applicable) × 1 — Reuse if in good condition

Fluids

• DOT 4 Brake Fluid — 1 qt

Preparation

1. Park vehicle on level ground and engage parking brake firmly
2. Place wheel chocks in front of the front wheels
3. Loosen rear wheel lug nuts while vehicle is on the ground (do not remove)
4. Raise rear of vehicle with floor jack at designated jacking point
5. Support vehicle securely with jack stands rated for vehicle weight
6. Remove rear wheel completely
7. Inspect brake hose routing and identify attachment points: caliper banjo bolt, frame bracket, and hard line connection
8. Clean brake hose fittings and surrounding area with wire brush if corroded
9. Have brake fluid catch container and rags ready for fluid spillage

Procedure

1. 1

   Prepare brake fluid reservoir
   Open the hood and locate the brake fluid reservoir. Remove the reservoir cap and place a clean rag over the opening to prevent contamination while allowing air to enter as fluid drains. Do not seal completely. Check fluid level and note current level for reference.
2. 2

   Disconnect brake hose from caliper
   Using a 14mm box wrench, hold the banjo bolt at the rear caliper connection. Position the brake fluid catch container beneath the caliper. Slowly unscrew the banjo bolt counterclockwise and remove completely. Allow brake fluid to drain into the container. Remove and discard both copper crush washers from each side of the banjo fitting. Immediately plug or cap the caliper port with a clean rag to minimize fluid loss and contamination.
   ⚠Brake fluid will drain from both the hose and caliper when disconnected. Keep catch container positioned to avoid fluid spilling onto brake components or vehicle finish.
3. 3

   Remove brake hose from bracket
   Locate the brake hose bracket mounted to the vehicle body or trailing arm. If a retaining clip is present, carefully remove it with pliers or a small flat screwdriver. If the bracket is bolted, use a 10mm socket to remove the bracket bolt. Pull the brake hose out of the bracket, noting the orientation and routing path for installation of the new hose.
   ℹ️Some models use a spring clip retainer while others use a bolted bracket. Inspect carefully to avoid breaking plastic clips.
4. 4

   Disconnect brake hose from hard line
   Using a 17mm flare nut wrench, carefully loosen the flare nut connecting the flexible brake hose to the steel hard line at the body or axle junction. Turn counterclockwise slowly to avoid rounding the fitting. Once loose, unscrew by hand and separate the hose from the hard line. Allow remaining fluid to drain into the catch container. Cover the hard line end with a clean rag or cap to prevent contamination.
   ⚠Use a flare nut wrench, not a standard open-end wrench, to prevent rounding off the soft brass or steel fitting.
5. 5

   Remove old brake hose
   Carefully remove the old brake hose from the vehicle, noting its routing path, any clips or guides it passes through, and the orientation of fittings. Inspect the old hose for cracks, bulging, or other damage to confirm replacement is necessary. Compare the new hose to the old hose to verify correct length and fitting types before proceeding.
6. 6

   Install new brake hose to hard line
   Route the new brake hose along the same path as the old hose. Start by connecting the hose to the hard line at the body or axle junction. Thread the flare nut by hand clockwise to ensure proper thread engagement. Once hand-tight, use the 17mm flare nut wrench to snug the fitting. Do not fully torque yet; leave slightly loose to allow hose alignment during final installation.
   ⚠Ensure the brake hose is not twisted during installation. The hose should follow a natural curve without torsion to prevent premature failure.
7. 7

   Secure brake hose in bracket
   Route the hose through the intermediate bracket on the trailing arm or body. Ensure the hose seats fully into the bracket. If using a spring clip, snap it into place firmly. If using a bolted bracket, install the bracket bolt and torque to specification using a torque wrench. Verify the hose can move slightly but is securely retained.
   Torque spec

   Brake Hose Bracket10 Nm (7 lb-ft)
8. 8

   Connect brake hose to caliper
   Place one new copper crush washer on each side of the banjo fitting (one against the caliper, one under the bolt head). Position the brake hose banjo fitting onto the caliper port, ensuring proper alignment with no twisting of the hose. Insert the banjo bolt through the fitting and thread it by hand into the caliper. Use a 14mm box wrench to torque the banjo bolt to specification.
   ⚠️New copper crush washers are mandatory. Reusing old washers will result in brake fluid leaks and potential brake failure.
   Torque spec

   Brake Hose Banjo Bolt25 Nm (18 lb-ft)
9. 9

   Final torque and alignment check
   With all connections made, verify the brake hose routing is correct with no twists, kinks, or contact with suspension components through full suspension travel. Manually compress and extend the suspension slightly to check clearance. Use the 17mm flare nut wrench to torque the hard line connection to the same torque as the banjo bolt (25 Nm / 18 lb-ft). Verify the hose does not turn more than 1/4 turn total from relaxed position when suspension moves.
   ⚠Brake hose must have adequate clearance from wheels, suspension arms, and steering components throughout full range of motion. Contact will cause hose failure.
10. 10

    Bleed rear brake circuit
    Locate the bleeder screw on the rear caliper (typically on the back side, facing toward vehicle rear). Attach clear vinyl tubing to the bleeder screw and submerge the other end in a container with a small amount of fresh DOT 4 brake fluid. Have an assistant pump the brake pedal 3-5 times and hold pressure. Open the bleeder screw 1/4 to 1/2 turn with an 8mm or 10mm wrench. Fluid and air will flow into the tubing. Close the bleeder screw before the pedal reaches the floor. Repeat this process until no air bubbles appear in the tubing and only clean fluid flows. Torque the bleeder screw to specification.
    ⚠Never allow the brake fluid reservoir to run dry during bleeding, or air will enter the ABS unit requiring professional equipment to bleed.
    ℹ️Check and refill the brake fluid reservoir frequently during the bleeding process.
    Torque spec

    Bleeder Screw14 Nm (10 lb-ft)
11. 11

    Check brake pedal feel
    With the engine off, pump the brake pedal repeatedly. The pedal should become firm and hold pressure. If the pedal remains soft or spongy, repeat the bleeding procedure on the affected corner. If pedal feel does not improve after multiple bleeding cycles, check all connections for leaks and verify proper installation. A consistently soft pedal may indicate air in the ABS unit requiring professional service.
12. 12

    Inspect for leaks
    Visually inspect all brake hose connections (banjo bolt at caliper, bracket, and hard line junction) for signs of brake fluid leakage. Wipe connections clean with a rag and have an assistant apply firm brake pedal pressure while you observe for seeping fluid. Check the area around the bleeder screw as well. Any leakage requires immediate correction before the vehicle is driven.
    ⚠️Even a small brake fluid leak can lead to complete brake failure. Do not drive the vehicle if any leakage is detected.
13. 13

    Reinstall wheel and lower vehicle
    Clean the wheel hub mounting surface and wheel mating surface. Install the wheel onto the hub, threading lug nuts by hand to prevent cross-threading. Tighten lug nuts in a star pattern with a lug wrench to snug (not final torque). Raise the vehicle slightly with the floor jack, remove jack stands, and lower the vehicle completely to the ground. Torque the lug nuts to specification in a star pattern using a torque wrench.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Top off brake fluid reservoir to the MAX line with fresh DOT 4 brake fluid, ensuring proper fluid level
2. Reinstall the brake fluid reservoir cap securely
3. Clean any spilled brake fluid from painted surfaces immediately with water
4. If replacing both rear hoses, repeat the entire procedure on the opposite side

Verification

• With the engine off, pump the brake pedal multiple times. It should build firm pressure and not sink to the floor
• Start the engine. The brake pedal should drop slightly as the brake booster engages, then remain firm
• Perform a stationary brake test: with the engine running, apply firm brake pressure for 30 seconds and verify the pedal does not slowly sink
• Visually inspect all brake hose connections one final time for any signs of fluid seepage or leakage
• Test drive the vehicle in a safe area at low speed (under 15 mph). Verify brakes engage smoothly without pulling to one side
• Perform several moderate brake applications from 25-30 mph in a safe location. Brakes should feel firm and responsive
• After test drive, re-inspect all connections for leaks while brakes are warm
• Check brake fluid level again after test drive and top off if necessary
• Monitor brake pedal feel and fluid level for the next several days of driving to ensure system integrity

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