Replace front brake rotors on a 2016-2024 Hyundai Tucson 2.5L AWD, including removal and reinstallation of calipers and caliper brackets.

Warnings

Tools required

Parts

• Front brake rotor (left) × 1 — Use OEM specification or quality aftermarket
• Front brake rotor (right) × 1 — Use OEM specification or quality aftermarket
• Rotor set screws (Phillips head) × 2 — M6 x 1.0mm, often reusable if not corroded

Preparation

1. Park vehicle on level ground, engage parking brake, and place transmission in Park
2. Check brake fluid reservoir level and remove cap to prevent pressure buildup when compressing pistons (or be prepared to open bleeder screws)
3. Loosen front wheel lug nuts while vehicle is on the ground, but do not remove
4. Lift front of vehicle using proper jacking points and secure with jack stands under the frame rails
5. Remove both front wheels completely
6. Verify you have the correct replacement rotors for your specific Tucson model year and trim

Procedure

1. 1

   Remove caliper slide pin bolts
   Locate the two caliper slide pin bolts on the rear of the caliper assembly (accessible from behind). Use a 17mm socket to remove both slide pin bolts. The caliper will now be free to pivot or lift off the rotor. Support the caliper weight as you remove the second bolt.
   Torque spec

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

   Remove and support brake caliper
   Carefully lift the caliper assembly off the rotor and bracket. Do NOT let the caliper hang by the brake hose, as this can damage the hose and cause brake failure. Use wire or a bungee cord to secure the caliper to the suspension spring or strut, ensuring no tension on the brake line.
   ⚠️Never allow the brake caliper to hang freely by the brake hose. This can cause internal hose damage and brake failure.
3. 3

   Remove caliper bracket bolts
   With the caliper removed and supported, locate the two caliper bracket bolts securing the bracket to the steering knuckle. These are larger bolts typically requiring an 18mm socket. Remove both bracket bolts completely and remove the caliper bracket assembly. Note: brake pads may come off with the bracket or remain on the rotor.
   Torque spec

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

   Remove rotor set screws
   Locate the Phillips head set screw(s) on the face of the rotor (typically one or two screws). Use a Phillips screwdriver to remove these screws. If corroded, use penetrating oil and allow time to soak, or use an impact driver. These screws are for assembly retention only and can be replaced if damaged.
   ⚠Set screws may be severely corroded. Avoid stripping the Phillips head by using proper size driver and penetrating oil if necessary.
   Torque spec

   Rotor Set Screws7 Nm (5 lb-ft)
5. 5

   Remove old brake rotor
   Pull the rotor straight off the wheel hub. If the rotor is stuck due to rust or corrosion, tap it from behind with a rubber mallet alternating around the circumference. Do not strike the rotor face or friction surface. If severely stuck, thread bolts into the threaded jacking holes (if present) to press the rotor off.
   ℹ️Rotors often corrode to the hub surface. Patience and penetrating oil may be required for removal.
6. 6

   Clean hub mounting surface
   Use a wire brush to thoroughly clean the wheel hub face where the rotor mounts, removing all rust, corrosion, and debris. This ensures proper rotor seating and prevents runout issues. Clean the hub pilot surface (center ring) as well. Wipe clean with brake cleaner.
   ℹ️Rust and debris on the hub surface can cause rotor runout, leading to vibration and uneven wear.
7. 7

   Prepare and install new rotor
   Clean new rotor thoroughly with brake cleaner to remove any protective coating or oils from manufacturing. Apply a thin layer of anti-seize to the hub pilot surface (center ring) to prevent future rotor seizure. Slide the new rotor onto the hub, aligning any alignment marks or holes. Rotor should sit flush against hub face.
   ⚠Do not get anti-seize on the rotor friction surfaces. Clean rotor faces with brake cleaner only.
8. 8

   Install rotor set screws
   Install the rotor set screw(s) and tighten to specification using a Phillips screwdriver and torque measurement if available. These screws only need to hold the rotor during assembly and are not critical to final retention (wheel holds rotor in place).
   Torque spec

   Rotor Set Screws7 Nm (5 lb-ft)
9. 9

   Reinstall caliper bracket
   Position the caliper bracket over the rotor and align the mounting holes with the steering knuckle. Apply threadlocker to the bracket bolt threads as recommended. Install both caliper bracket bolts and torque to specification in a cross pattern. Ensure bracket is securely mounted with no movement.
   ⚠️Caliper bracket bolts are critical fasteners. Ensure proper torque is achieved and threadlocker is applied as specified.
   Torque spec

   Caliper Bracket Bolts102 Nm (75 lb-ft)
10. 10

    Compress caliper pistons if necessary
    Before reinstalling the caliper, check if the caliper pistons need to be compressed to fit over the new rotor (especially if new pads are being installed). Use a C-clamp or brake piston tool to slowly compress the piston(s) back into the caliper bore. Monitor brake fluid reservoir for overflow. This step may not be necessary if rotors are the same thickness as the old ones and pads are reused.
    ⚠Compressing pistons forces brake fluid back to the reservoir. Ensure reservoir cap is loose or remove fluid to prevent overflow and potential ABS damage.
11. 11

    Reinstall brake caliper
    Remove the caliper from its supported position. Apply fresh silicone brake grease to the slide pin bolts (shaft portion only, not threads). Position the caliper over the rotor and bracket, ensuring brake pads are properly aligned on both sides of the rotor. Install both slide pin bolts and torque to specification.
    ⚠Ensure brake pads are properly seated in the caliper bracket and that the caliper moves freely on the slide pins before tightening.
    Torque spec

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

    Repeat for opposite side
    Repeat steps 1-11 for the opposite front wheel to replace the second rotor. Brake components should always be serviced in axle pairs to ensure even braking performance.
    ℹ️Always replace rotors in pairs (both front or both rear) to maintain balanced braking.
13. 13

    Reinstall wheels and torque lug nuts
    Mount both front wheels onto the hubs. Install lug nuts and tighten by hand. Lower the vehicle until the wheels just contact the ground (not fully weighted). Torque lug nuts to specification in a star pattern. Fully lower the vehicle and remove jack stands.
    ⚠Always torque lug nuts in a star pattern to ensure even wheel seating and prevent warping.
    Torque spec

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

    Pump brake pedal and check fluid
    Before attempting to move the vehicle, sit in the driver's seat and pump the brake pedal several times until it feels firm. The first few pedal applications will feel soft as the caliper pistons extend to contact the new rotors. Check brake fluid reservoir level and top off with DOT 4 brake fluid if necessary. Reinstall reservoir cap securely.
    ⚠️Do not attempt to drive the vehicle until the brake pedal feels firm. Failure to pump up the brakes will result in no braking on first application.

Reassembly

1. Ensure all caliper bracket bolts and slide pin bolts are torqued to specification
2. Verify brake fluid level is between MIN and MAX marks on reservoir
3. Confirm no brake fluid leaks are present at any connections
4. Ensure wheels are properly torqued in a star pattern

Verification

• Pump brake pedal until firm resistance is felt before starting engine
• Start engine and verify brake pedal remains firm with slight drop when power assist engages
• Perform a low-speed brake test (5-10 mph) in a safe area to confirm proper brake function
• Listen for any unusual noises during initial brake applications (light squeaking is normal with new rotors)
• Verify no brake warning lights are illuminated on the dashboard
• Check for even braking with no pulling to either side
• Perform bedding-in procedure: make 20-30 gradual stops from 30-40 mph to properly mate pads to new rotors, allowing cooling between stops
• Re-check lug nut torque after driving 50-100 miles

More procedures for this vehicle