Brake Pads and Rotors - Rear

Replace rear brake pads and rotors on 2016-2024 Hyundai Tucson 2.5L AWD to restore braking performance and eliminate noise or vibration.

Warnings

Tools required

Parts

• Rear brake pads (axle set) × 1 — Use OEM specification or quality aftermarket
• Rear brake rotors × 2 — Use OEM specification or quality aftermarket
• Brake pad hardware kit (clips and shims) × 1 — Often included with pad set

Fluids

• DOT 4 Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level surface and engage parking brake firmly
2. Loosen rear wheel lug nuts 1/4 turn while vehicle is on ground
3. Lift rear of vehicle using floor jack at designated rear jacking point and secure with jack stands under frame rails
4. Remove rear wheels completely
5. Open brake fluid reservoir cap and remove approximately 1/4 of fluid with turkey baster or syringe to prevent overflow when compressing pistons. Dispose of old fluid properly
6. Clean work area and prepare tools. Have brake cleaner and clean rags ready

Procedure

1. 1

   Remove caliper slide pin bolts
   Locate the two caliper slide pin bolts on the rear of the caliper body (13mm hex). Remove the lower slide pin bolt completely. Loosen but do not remove the upper slide pin bolt, allowing the caliper to pivot upward on the upper pin.
   Torque spec

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

   Secure caliper and remove old pads
   Pivot the caliper upward to access the brake pads. Support the caliper weight with wire or bungee cord attached to the suspension or chassis - do not allow it to hang by the brake hose. Remove the old brake pads from the caliper bracket. Note the position of any anti-rattle clips or shims for reinstallation.
3. 3

   Remove caliper bracket
   Remove the upper caliper slide pin bolt completely and carefully move the caliper assembly aside, continuing to support its weight. Using a 17mm socket, remove both caliper bracket bolts (top and bottom) that secure the bracket to the knuckle. Remove the caliper bracket completely. Inspect bracket for wear or damage.
   Torque spec

   Caliper Bracket Bolts102 Nm (75 lb-ft)
4. 4

   Remove old rotor
   Remove the rotor from the hub. It may be held by a small Phillips screw - remove if present. If rotor is stuck due to corrosion, tap around the hat section with a rubber mallet or use penetrating oil. Do not strike the braking surface. Thread M8x1.25 bolts into threaded holes (if present) to push rotor off evenly.
   ⚠Inspect wheel hub surface for damage or excessive rust buildup. Clean hub face thoroughly with wire brush before installing new rotor.
5. 5

   Prepare hub and install new rotor
   Clean the hub mounting surface with a wire brush to remove rust and debris. Ensure hub surface is smooth and flat. Clean new rotor thoroughly with brake cleaner to remove protective coating. Spray both sides and wipe dry. Place new rotor onto hub, ensuring it sits flush. Install Phillips retaining screw if equipped (hand tight only - this is a positioning screw).
6. 6

   Clean and prepare caliper bracket
   Thoroughly clean the caliper bracket, removing all old grease, rust, and debris from pad contact surfaces and slide pin bores. Use a wire brush and brake cleaner. Inspect bracket hardware slots where pads slide - these must be smooth. Install new anti-rattle clips and shims from hardware kit if included with new pads.
7. 7

   Reinstall caliper bracket
   Apply medium-strength thread locker to the caliper bracket bolt threads. Position bracket over rotor and align with mounting holes on knuckle. Install both bracket bolts and tighten to specification in a cross pattern. Verify bracket is secure and properly aligned with rotor.
   ⚠Thread locker is required on caliper bracket bolts. Bolts loosening during operation can cause complete brake failure.
   Torque spec

   Caliper Bracket Bolts102 Nm (75 lb-ft)
8. 8

   Compress caliper piston
   Before compressing piston, verify brake fluid was removed from reservoir in preparation steps. Use C-clamp or brake piston tool to slowly compress the caliper piston fully into its bore. Position the clamp on the piston face and the back of the caliper body. Compress slowly and evenly. For electronic parking brake calipers (if equipped on rear), piston may need to be rotated while compressing - verify your specific model.
   ⚠Some 2016-2024 Tucson models may have electronic parking brake integration requiring a scan tool to retract calipers. Verify your specific vehicle configuration before proceeding.
9. 9

   Install new brake pads
   Apply a thin layer of silicone brake grease to the pad backing plates where they contact the caliper bracket and pistons (not on friction material). Install the inner and outer brake pads into the caliper bracket, ensuring they are properly seated in the hardware clips. Verify pads move freely in bracket.
10. 10

    Lubricate and reinstall caliper
    Remove caliper slide pins from caliper completely. Clean pins thoroughly and inspect rubber boots for tears or damage. Apply silicone brake grease to the full length of each slide pin. Reinstall pins into caliper body, ensuring boots are properly seated. Position caliper over new pads and align with slide pin bolt holes on bracket.
11. 11

    Install and torque slide pin bolts
    Apply silicone brake grease to the slide pin bolt threads. Install both upper and lower caliper slide pin bolts. Tighten both bolts to specification using torque wrench. Verify caliper is centered over rotor and pads are positioned correctly on both sides.
    Torque spec

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)
12. 12

    Repeat for opposite side
    Perform steps 1-11 on the opposite rear wheel, replacing pads and rotor using identical procedure. Maintain consistency in torque values and lubrication points.
13. 13

    Reinstall wheels
    Clean wheel mounting surfaces on hub. Install rear wheels and thread lug nuts by hand to ensure proper seating. Tighten lug nuts in a star pattern with torque wrench to specification. Do not fully tighten until vehicle is lowered.
    Torque spec

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

    Lower vehicle and perform final checks
    Lower vehicle from jack stands to ground using floor jack. Remove jack stands and lower completely. With vehicle on ground, perform final torque on lug nuts in star pattern to specification. Check brake fluid reservoir level and top off with fresh DOT 4 fluid to MAX line. Reinstall reservoir cap securely.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)
15. 15

    Restore brake pedal and test
    Before moving vehicle, pump brake pedal firmly 15-20 times until pedal becomes firm and reaches normal height. This is CRITICAL - pistons must contact pads before driving. Pedal should feel firm and return to normal position. Start engine and verify brake warning lights are off. Test brakes at low speed in a safe area before normal driving.
    ⚠️DO NOT DRIVE VEHICLE until brake pedal is pumped to restore hydraulic pressure. First pedal press will go to floor - this is normal after piston compression.

Reassembly

1. Ensure all caliper slide pin bolts are torqued to specification and lubricated properly
2. Verify wheel lug nuts are torqued in star pattern after vehicle is on ground
3. Check brake fluid level is at MAX line with fresh DOT 4 fluid
4. Dispose of old brake fluid, pads, and rotors according to local regulations

Verification

• Pump brake pedal until firm - pedal should not sink to floor and should maintain pressure
• Start engine and verify no brake warning lights or ABS lights are illuminated
• Perform test stops in safe area at low speed (under 15 mph) before normal driving
• Check for unusual noises, vibrations, or pulling to one side during braking
• Perform proper bed-in procedure: 15-20 moderate stops from 40 mph with cool-down periods between stops
• After 50-100 miles, re-check lug nut torque and brake fluid level
• Avoid aggressive braking for first 200 miles to allow pads to properly seat to rotors
• If brake pedal feels soft, unusual noises occur, or vehicle pulls during braking, stop driving immediately and seek professional inspection

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