Assumption: Your Tucson has an electronic parking brake (EPB). If yours has a manual parking brake lever/pedal, follow the “Non-EPB” notes in the steps.

🔧 Tucson - Rear Brake Pads & Rotor Replacement

You’ll remove the rear wheels, take off the rear calipers and brackets, replace the pads and rotors, then reassemble and bed-in the new brakes. The key on your Tucson is handling the parking brake system correctly so the rear caliper pistons retract safely.

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

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⚠️ Safety & Precautions

• 🧯 Support the Tucson with jack stands; never rely on a floor jack.
• 🧤 Brakes make dust; wear gloves and safety glasses and use brake cleaner (don’t blow dust with compressed air).
• 🔥 Rotors can be hot; let everything cool before you start.
• 🛑 If equipped with EPB: put EPB in service/maintenance mode before removing calipers; do not force the piston back with a clamp.
• 🔋 Battery disconnect is typically not required for pads/rotors, but keep the ignition OFF during EPB service mode steps.

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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
• 14mm socket
• 17mm socket
• Torque wrench (10-200 Nm range)
• Flat trim/pry tool
• Wire brush
• Bungee cord
• Brake caliper piston tool (specialty)
• Scan tool with EPB service mode (specialty)
• Brake cleaner
• 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 - Qty: 2
• Rear brake hardware kit (abutment clips) - Qty: 1
• Brake lubricant (silicone or synthetic brake grease) - Qty: 1
• Brake cleaner - Qty: 1
• DOT 3 brake fluid - Qty: 1 (small bottle for top-off)

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📋 Before You Begin

• Park on level ground, steering straight, and place wheel chocks at the front wheels.
• Make sure the parking brake is released before lifting the rear.
• Loosen rear lug nuts 1/2 turn with a 21mm socket and breaker bar before lifting.
• If equipped with EPB: plan to use a scan tool with EPB service mode (this retracts the parking brake motor so the caliper can be serviced safely).

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Lift and secure the rear

• Use a floor jack (rated 3-ton minimum) to lift the rear at the approved rear jacking point.
• Set the Tucson onto jack stands (rated 3-ton minimum) at the rear support points.
• Remove the rear wheels using a 21mm socket.

Step 2: Put the EPB into service mode (EPB-equipped)

• Connect a scan tool with EPB service mode (specialty).
• Run the scan tool function to retract/release rear EPB actuators (often labeled “EPB Maintenance Mode” or “Pad Replacement Mode”).
• If you don’t have EPB service mode, don’t continue.
• Non-EPB note: If your Tucson has a manual parking brake, skip this step.

Step 3: Remove the rear caliper

• Turn the steering wheel slightly if needed for access (rear is usually straight-on access).
• Remove the two caliper slide pin bolts using a 14mm socket and ratchet.
• Lift the caliper off the bracket and support it with a bungee cord so it doesn’t hang by the brake hose.
• Torque spec (reassembly): Torque caliper slide pin bolts to 25-30 Nm (18-22 ft-lbs).

Step 4: Remove pads and caliper bracket

• Slide the old pads out of the bracket by hand or using a flat trim/pry tool gently.
• Remove the caliper bracket bolts using a 17mm socket and breaker bar.
• Remove the bracket from the knuckle.
• Torque spec (reassembly): Torque rear caliper bracket bolts to 80-100 Nm (59-74 ft-lbs).

Step 5: Remove the rear rotor

• Pull the rotor straight off the hub.
• If the rotor is stuck from rust, tap around the hat area (the “top hat” center section) while pulling; use a breaker bar carefully as leverage if needed.
• Clean the hub face with a wire brush and wipe with brake cleaner to help prevent rotor wobble (pulsation).

Step 6: Install the new rotor

• Spray both sides of the new rotor with brake cleaner and wipe with shop towels to remove protective oil.
• Install the rotor onto the hub.
• Hold it in place temporarily by hand (or thread on one lug nut a few turns using a 21mm socket so it stays seated while you work).

Step 7: Service the bracket and install new hardware

• Remove old abutment clips (hardware) from the bracket using a flat trim/pry tool.
• Clean pad contact areas on the bracket with a wire brush (this helps the pads slide smoothly).
• Install new abutment clips from the rear brake hardware kit.
• Apply a thin film of brake lubricant where pads slide on the clips (not on pad friction material).

Step 8: Retract the rear caliper piston

• EPB-equipped: With EPB in service mode, retract the piston using a brake caliper piston tool (specialty) as needed to make room for new thicker pads.
• Non-EPB note: Many rear calipers require the piston to be rotated while pushing in; the brake caliper piston tool does both.
• Check the brake fluid level; if it rises near “MAX,” remove a small amount safely before it spills (use shop towels to protect paint).
• Go slow; a torn boot causes caliper failure.

Step 9: Install new pads and reinstall bracket/caliper

• Install the new pads into the bracket by hand (inner/outer as designed).
• Reinstall the bracket using a 17mm socket and torque wrench.
• Torque to 80-100 Nm (59-74 ft-lbs).
• Reinstall the caliper over the new pads and install slide pin bolts using a 14mm socket and torque wrench.
• Torque to 25-30 Nm (18-22 ft-lbs).

Step 10: Exit EPB service mode (EPB-equipped)

• Use the scan tool with EPB service mode (specialty) to command EPB out of maintenance mode (often “Close/Apply” or “End Maintenance”).
• Verify the EPB applies and releases normally before driving.

Step 11: Reinstall wheels and torque lug nuts

• Reinstall the 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 90-110 Nm (66-81 ft-lbs).

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✅ After Repair

• With the engine OFF, pump the brake pedal 10-15 times until it feels firm (this seats the pistons).
• Check brake fluid level and top off with DOT 3 brake fluid if needed.
• Test EPB operation: apply/release several times (EPB-equipped).
• Do a careful test drive: low-speed stops first, listen for grinding, and confirm straight braking.
• Bed-in new pads (typical): 6-10 moderate stops from ~30–40 mph to ~5 mph, with cool-down driving between stops. Avoid hard stops for 200 miles.

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💰 DIY vs Shop Cost

Shop Cost: $450-$900 (parts + labor)

DIY Cost: $160-$380 (parts only)

You Save: $290-$520 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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