Brake Rotors - Rear Pair

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

Warnings

Tools required

Parts

• Rear brake rotor (pair) × 2 — Use OEM or equivalent meeting Hyundai specifications
• Rotor set screws (if corroded) × 2 — M5 x 10mm Phillips

Fluids

• DOT 4 Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level, solid ground and engage parking brake firmly
2. Place wheel chocks in front of both front wheels
3. Open brake fluid reservoir and remove approximately 1/4 of the fluid with a turkey baster or syringe to prevent overflow when compressing pistons. Dispose of old fluid properly
4. Loosen rear wheel lug nuts 1/2 turn while vehicle is on ground
5. Lift rear of vehicle with floor jack at designated jacking points and support on jack stands placed under the frame rails
6. Remove rear wheels completely and set aside
7. Verify vehicle is stable on jack stands before working underneath

Procedure

1. 1

   Access and inspect brake assembly
   Inspect the rear brake assembly through the wheel opening. Identify the caliper slide pin bolts (two 17mm bolts on the inboard side of the caliper). Note the position of the brake hose and ABS wire routing. Check for any signs of leaking brake fluid, which would indicate additional repairs are needed.
2. 2

   Remove caliper slide pin bolts
   Using a 17mm socket or wrench, remove the two caliper slide pin bolts from the rear of the caliper assembly. These bolts pass through rubber bushings and may require some force to break loose. Keep track of any washers or bushings on the bolts. The caliper is now free to pivot away from the rotor.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
3. 3

   Remove and support caliper
   Carefully lift the caliper assembly up and away from the rotor and brake pads. Do NOT disconnect the brake hose. Use wire, a bungee cord, or a suitable hook to hang the caliper from the suspension or frame. Ensure there is no tension or strain on the rubber brake hose. The caliper must be supported securely and not hanging by the hose.
   ⚠️Never allow the caliper to hang by the brake hose. This can cause internal damage to the hose and lead to brake failure.
4. 4

   Remove brake pads
   Remove the inner and outer brake pads from the caliper bracket. Note their orientation and position for reassembly reference, though you should install new pads with new rotors. Remove the pad shims and anti-rattle clips if present. Inspect the caliper slide pins and boots for damage or wear.
5. 5

   Remove rotor set screws
   If present, remove the Phillips head rotor set screw(s) that hold the rotor to the hub. These screws are often corroded and may require significant force or an impact driver. If the screw head strips, it may need to be drilled out. In many cases, these screws can be omitted during reassembly as the wheel lug nuts secure the rotor.
   ⚠Set screws may be severely corroded. Use penetrating oil and allow time to soak before attempting removal. An impact driver can help prevent stripping.
   Torque spec

   Rotor Set Screws7 Nm (5 lb-ft)
6. 6

   Remove old rotor
   Pull the rotor straight off the hub. If the rotor is seized to the hub due to corrosion, tap it from behind with a brass or plastic hammer. Do not strike the rotor face. You may need to thread bolts into the threaded holes in the rotor face (if present) to push it off the hub. Avoid damaging the wheel studs or hub surface.
7. 7

   Clean hub surface
   Use a wire brush to thoroughly clean the hub mounting surface, removing all rust, corrosion, and debris. The hub face must be clean and flat to prevent rotor runout and pulsation. Clean the wheel studs and threads as well. Wipe down with brake cleaner and allow to dry.
8. 8

   Prepare and install new rotor
   Remove the new rotor from packaging. Clean both sides thoroughly with brake cleaner to remove any protective oil coating. Allow to dry completely. Slide the new rotor onto the hub, ensuring it seats completely flat against the hub face. If using set screws, install and tighten them to specification using a Phillips screwdriver.
   ℹ️New rotors have a protective coating that must be removed with brake cleaner. Failure to do so will cause smoking and poor braking performance.
   Torque spec

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

   Compress caliper pistons
   Before reinstalling the caliper, the pistons must be compressed to accommodate the new, thicker brake pads and rotor. Use a brake caliper piston tool or large C-clamp to slowly and evenly compress the piston(s) back into the caliper bore. Work slowly to avoid damaging the piston seals. For rear calipers with integrated parking brake, you may need to rotate the piston clockwise while compressing (check your specific model).
   ⚠Compressing pistons forces brake fluid back into the reservoir. Ensure you removed fluid earlier to prevent overflow. Monitor the reservoir and remove fluid if needed.
10. 10

    Clean and lubricate slide pins
    Remove the caliper slide pins from the bracket if accessible. Clean the pins and bores thoroughly with brake cleaner. Inspect the rubber boots for tears or damage and replace if necessary. Apply a thin, even coating of silicone brake grease to the slide pin shafts (not the threads). Reinstall the pins into the bracket, ensuring boots are properly seated.
    Torque spec

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)
11. 11

    Install brake pads and hardware
    Install new brake pad hardware, shims, and anti-rattle clips according to the pad manufacturer's instructions. Install the inner and outer brake pads into the caliper bracket, ensuring they are properly seated in the hardware. Verify pads move freely in the bracket.
12. 12

    Reinstall caliper assembly
    Remove the caliper from its support wire or hook. Carefully position the caliper over the brake pads and rotor, aligning the slide pin bolt holes. Ensure the brake hose is not twisted or kinked. Insert both caliper slide pin bolts through the caliper and into the bracket. Thread them by hand first to ensure proper alignment.
13. 13

    Torque caliper slide pin bolts
    Using a torque wrench, tighten both caliper slide pin bolts to 35.0 Nm (26 lb-ft) in a crisscross pattern. Ensure the caliper moves freely on the slide pins after torquing. The caliper should slide smoothly without binding. Verify the brake hose has adequate clearance and is not stretched or kinked.
    Torque spec

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)
14. 14

    Repeat for opposite side
    Repeat steps 1 through 13 for the opposite rear brake rotor and caliper assembly. It is critical that both rear rotors are replaced as a pair to ensure even braking performance.
15. 15

    Reinstall wheels and lower vehicle
    Reinstall the rear wheels, threading lug nuts by hand first. Tighten lug nuts in a star pattern with a hand wrench until snug. Lower the vehicle from the jack stands to the ground. With the vehicle on the ground and full weight on the wheels, torque the lug nuts to 140.0 Nm (103 lb-ft) in a star pattern using a torque wrench.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Check brake fluid level in the reservoir and top off to the MAX line with fresh DOT 4 brake fluid if necessary
2. DO NOT start the engine or drive the vehicle yet
3. Pump the brake pedal slowly and firmly 10-15 times until it feels firm and returns to normal height. The pedal will initially go to the floor as the pistons extend to contact the new pads
4. Check for any brake fluid leaks around caliper connections and bleeder screws
5. Verify the parking brake operates correctly and releases fully

Verification

• With the vehicle still parked, press the brake pedal firmly. It should feel firm and not sink to the floor. If the pedal is soft or spongy, the system may need bleeding
• Perform a low-speed test drive in a safe area. Test brakes at 5-10 mph to verify basic function before proceeding
• If brakes feel normal, perform the bedding-in procedure: make 20-30 moderate stops from 40 mph down to 10 mph with 30 seconds between stops to allow cooling. Avoid coming to a complete stop during bedding. This transfers pad material to the rotor and prevents glazing
• After bedding, verify no unusual noises, vibrations, or pulling to one side during braking
• Re-check all lug nut torque after driving 50-100 miles
• Monitor brake performance over the next few days. New rotors and pads require several hundred miles to fully seat and achieve maximum performance
• If you experience any brake pedal pulsation, pulling, unusual noises, or reduced braking performance, have the system inspected by a professional immediately

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