Replace rear brake pads on a 2016-2024 Hyundai Tucson 2.5L AWD, including caliper service and proper torque specifications.

Warnings

Tools required

Parts

• Rear brake pad set (left and right) × 1 — Use OEM specification or equivalent ceramic pads
• Brake hardware/anti-rattle clips (if not included with pads) × 1 — Usually included with pad set

Fluids

• DOT 4 Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level ground and engage parking brake. Place wheel chocks at front wheels.
2. Before lifting vehicle, loosen rear wheel lug nuts approximately one turn while wheels are still on the ground.
3. Lift rear of vehicle using floor jack at designated rear jacking point and secure on jack stands at proper support points per owner's manual.
4. Remove rear wheels completely and set aside in safe location.
5. Open brake fluid reservoir cap under hood and remove approximately 1-2 oz of fluid with turkey baster to prevent overflow when compressing pistons. Dispose of old fluid properly.
6. Inspect brake components for damage, leaking fluid, or excessive rotor wear before proceeding.

Procedure

1. 1

   Access rear brake caliper
   Locate the rear brake caliper assembly. Identify the two caliper slide pin bolts on the rear side of the caliper (typically 17mm heads). Clean area around bolts with wire brush or brake cleaner to prevent contamination.
2. 2

   Remove lower caliper slide pin bolt
   Using a 17mm wrench or socket, remove only the LOWER caliper slide pin bolt. Keep the upper bolt installed to allow the caliper to swing upward like a door. Inspect the slide pin for damage, corrosion, or torn boots. Clean pin thoroughly and inspect rubber boot for tears.
3. 3

   Pivot caliper upward
   Carefully rotate the brake caliper upward on the remaining upper slide pin bolt, pivoting it away from the brake rotor and pads. Support the caliper weight - do not let it hang by the brake hose. Use a bungee cord or wire to secure caliper to suspension component if needed.
4. 4

   Remove old brake pads and hardware
   Remove the outboard and inboard brake pads from the caliper bracket. Note the orientation and position of any anti-rattle clips, shims, or springs. Remove and discard old hardware clips from the caliper bracket. Photograph arrangement before removal if helpful for reassembly.
5. 5

   Inspect caliper bracket and rotor
   Clean caliper bracket mounting surfaces where pads slide using wire brush. Remove rust and debris from pad abutment areas. Inspect rotor surface for scoring, heat cracks, or excessive wear. Measure rotor thickness if gauge available and compare to minimum thickness specification stamped on rotor hat.
6. 6

   Install new brake hardware
   Install new anti-rattle clips and hardware included with brake pad set onto caliper bracket. Ensure clips are fully seated and oriented correctly per instructions included with pads. Apply thin layer of silicone brake grease to pad abutment surfaces on bracket where pads will slide (avoid getting grease on rotor or pad friction material).
7. 7

   Compress caliper piston
   Before installing new pads, the caliper piston must be compressed fully into its bore to accommodate thicker new pads. Use C-clamp or brake piston compression tool against the piston face (using old brake pad as a buffer) and slowly compress piston completely. Monitor brake fluid reservoir to ensure it does not overflow as piston retracts.
   ⚠Compress piston slowly and evenly. Do not cock piston at an angle or force it. If piston does not compress smoothly, caliper may need service or replacement.
8. 8

   Install new brake pads
   Install new inboard brake pad into caliper bracket, ensuring it seats properly in hardware clips and against piston. Install new outboard brake pad, ensuring it seats in bracket and any retaining clips. Verify pads are positioned correctly and move freely in bracket.
9. 9

   Lubricate and reinstall caliper
   Apply thin coat of silicone brake grease to both caliper slide pins (upper and lower) and inside pin boots. Rotate caliper back down over new brake pads. Align lower slide pin with its bore in the caliper bracket.
   Torque spec

   Caliper Slide Pin Bolts30 Nm (22 lb-ft)
10. 10

    Install and torque caliper slide pin bolt
    Thread lower caliper slide pin bolt by hand to ensure proper threading. Tighten to 35 Nm (26 lb-ft) using torque wrench. Verify upper slide pin bolt remains tight at same specification. Ensure caliper is properly centered over rotor and pads.
    ⚠️Caliper slide pin bolts are CRITICAL fasteners. Under-torquing can cause caliper failure and loss of braking. Over-torquing can strip threads. Use calibrated torque wrench.
    Torque spec

    Caliper Slide Pin Bolts30 Nm (22 lb-ft)
11. 11

    Repeat for opposite side
    Perform steps 1-10 on the opposite rear brake assembly. Both rear brakes must be serviced together to maintain balanced braking performance.
12. 12

    Reinstall wheels
    Clean wheel mounting surfaces on hub with wire brush. Mount rear wheels onto hubs. Thread lug nuts by hand to prevent cross-threading. Snug lug nuts in star pattern but do not fully tighten yet.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)
13. 13

    Lower vehicle and torque wheels
    Carefully raise vehicle slightly off jack stands, remove stands, and lower vehicle completely to ground. Torque wheel lug nuts to 140 Nm (103 lb-ft) in star pattern using torque wrench. Recheck all lug nuts after initial torque.
    ⚠️Improperly torqued lug nuts can cause wheel detachment while driving. Always use star pattern and calibrated torque wrench.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)
14. 14

    Restore brake pedal and check fluid level
    With vehicle on ground and engine OFF, pump brake pedal slowly 10-15 times until firm resistance is felt. Pedal should become firm and hold. Check brake fluid reservoir and top off to MAX line with fresh DOT 4 brake fluid if needed. Securely reinstall reservoir cap.

Reassembly

1. Ensure brake fluid reservoir is filled to proper level with DOT 4 fluid and cap is secure
2. Verify all caliper slide pin bolts are torqued to specification on both rear brakes
3. Confirm wheel lug nuts are torqued to 140 Nm (103 lb-ft) in star pattern
4. Remove wheel chocks from front wheels

Verification

• With engine off, pump brake pedal multiple times. Pedal should feel firm and not sink to floor. If pedal feels soft or spongy, system may need bleeding.
• Start engine and verify brake warning light is not illuminated on dashboard.
• Test brakes at low speed (under 5 mph) in safe area to verify proper operation before road use.
• Listen for any unusual noises during initial brake applications. Light squealing during first few stops is normal as pads seat.
• After first 50-100 miles, recheck wheel lug nut torque.
• Bedding procedure: Perform 10-15 moderate stops from 40-45 mph down to 15-20 mph with 30 seconds between stops to properly bed new pads to rotors. Avoid hard stops during first 200 miles.

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