🔧 Tucson - Rear Brake Pads & Rotor Replacement

You’ll remove the rear wheels, swap the rear brake pads and rotors, then reset the caliper piston and reassemble with the correct lubrication and torque. This restores braking performance and prevents vibration/noise from worn pads or warped rotors.

Difficulty Level: Intermediate | Estimated Time: 2-4 hours

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⚠️ Safety & Precautions

• 🛑 Support your Tucson on jack stands; never rely on a jack.
• 🔥 Brakes can be hot; let everything cool before touching.
• 🧪 Avoid inhaling brake dust; use brake cleaner, not compressed air.
• 🧱 Chock the front wheels and keep the transmission in P.
• 🧯 Brake fluid damages paint; keep rags handy and wipe spills fast.
• 🔧 Do not press the brake pedal with a caliper removed.

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🔧 Required Tools

You'll need the following tools for this repair:

• Floor jack (rated 3-ton minimum)
• Jack stands (rated 3-ton minimum)
• Wheel chocks
• 21mm socket
• 3/8" drive ratchet
• 1/2" drive breaker bar
• Torque wrench (20-150 ft-lbs range)
• 14mm socket
• 17mm socket
• 14mm box wrench
• Flat-blade screwdriver
• Needle-nose pliers
• Brake caliper piston rewind tool (specialty)
• Wire hook or bungee cord
• Wire brush
• Rubber mallet
• #3 Phillips screwdriver
• Impact screwdriver (specialty)
• Brake cleaner spray
• Shop towels
• Nitrile gloves
• Safety glasses

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Rear brake pad set - Qty: 1
• Rear brake rotors - Replace in pairs - Qty: 2
• Rear brake hardware kit (abutment clips) - Qty: 1
• Brake caliper slide pin grease (silicone) - Qty: 1
• Brake cleaner - Qty: 1
• DOT 3 brake fluid - Qty: 1 quart

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📋 Before You Begin

• Park on level ground, set the rear parking brake to OFF, and chock the front wheels.
• Loosen rear lug nuts 1/2 turn using a 21mm socket and breaker bar before lifting.
• Open the hood and loosen the brake fluid reservoir cap (leave it sitting on top). This helps the caliper piston retract.
• If your rear caliper piston has notches, it must be turned while pushing in. A caliper piston rewind tool is a tool that presses and rotates the piston at the same time.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Lift the rear and remove the wheels

• Use a floor jack to lift the rear at the approved rear jacking point.
• Place jack stands under the rear support points and lower onto them.
• Remove the lug nuts using a 21mm socket and take off both rear wheels.

Step 2: Locate the caliper, then remove the caliper bolts

• Turn the steering wheel straight and look at the rear brake assembly: caliper (outer part) over the rotor.
• Remove the lower and upper caliper slide bolts using a 14mm socket and ratchet.
• Lift the caliper off the bracket. If it’s tight, gently pry using a flat-blade screwdriver.
• Hang the caliper from the suspension using a wire hook or bungee cord. Do not let it hang by the hose.

Step 3: Remove old pads and hardware

• Slide the old brake pads out of the bracket by hand.
• Remove the pad abutment clips (hardware) using a flat-blade screwdriver.
• Clean the bracket pad lands with a wire brush and spray with brake cleaner spray.

Step 4: Remove the caliper bracket

• Remove the caliper bracket bolts using a 17mm socket and breaker bar.
• Remove the bracket and set it aside.
• When reinstalling later: Torque to 78-98 Nm (58-72 ft-lbs).

Step 5: Remove the rotor

• If equipped with rotor retaining screws, remove them using a #3 Phillips screwdriver. If stuck, use an impact screwdriver (specialty).
• Pull the rotor off. If it’s rust-stuck, tap the rotor hat with a rubber mallet to free it.
• Clean the hub face with a wire brush so the new rotor sits flat.

Step 6: Install the new rotor

• Spray the new rotor with brake cleaner spray and wipe with shop towels to remove shipping oil.
• Install the rotor onto the hub. If you have retaining screws, reinstall them using a #3 Phillips screwdriver (snug only).

Step 7: Service slide pins and reinstall the bracket

• Pull the slide pins out of the bracket (one at a time). Use a 14mm box wrench only if you need to hold the pin while loosening a bolt.
• Clean old grease off, then apply a thin coat of brake caliper slide pin grease (silicone) and reinstall the pins.
• Reinstall the caliper bracket using a 17mm socket and ratchet.
• Torque to 78-98 Nm (58-72 ft-lbs).

Step 8: Retract the caliper piston

• Check the piston face. If you see notches, use the brake caliper piston rewind tool (specialty) to push and turn the piston clockwise until it bottoms.
• Go slowly; watch the brake fluid level.
• If the reservoir starts to overflow, remove some fluid with shop towels (do not spill on paint).

Step 9: Install new hardware and pads

• Install the new abutment clips from the rear brake hardware kit into the bracket by hand (use a flat-blade screwdriver to fully seat if needed).
• Install the new pads into the bracket.
• If your pad set includes wear indicators/squealers, install them in the same position as the originals.

Step 10: Reinstall the caliper

• Position the caliper over the new pads and rotor.
• Install the caliper slide bolts using a 14mm socket and ratchet.
• Torque to 28-34 Nm (21-25 ft-lbs).
• Make sure the brake hose is not twisted.

Step 11: Reinstall wheels and torque lug nuts

• Reinstall wheels and hand-thread lug nuts.
• Lower the Tucson off the jack stands using the floor jack.
• Tighten lug nuts in a star pattern using a torque wrench: Torque to 88-108 Nm (65-79 ft-lbs).

Step 12: Restore pedal and parking brake

• Before driving, pump the brake pedal 10-15 times until it feels firm.
• Apply and release the parking brake a few times to self-adjust.
• Top off brake fluid if needed (use DOT 3 brake fluid) and tighten the reservoir cap.

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✅ After Repair

• With the engine on, confirm the brake pedal is firm and doesn’t sink.
• Do a slow test drive and confirm no grinding, pulling, or brake warning lights.
• Bed-in the pads: do 6-8 moderate stops from 40 mph to 10 mph, allowing a little cooling time between stops.
• Recheck brake fluid level and look for leaks around each caliper.

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💰 DIY vs Shop Cost

Shop Cost: $450-$850 (parts + labor)

DIY Cost: $160-$350 (parts only)

You Save: $290-$500 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 2-3 hours.

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🎯 Ready to get started?

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