🔧 Tucson - Rear Brake Pads & Rotors Replacement

This repair replaces the rear brake pads and rear brake rotors on your Tucson. The rear brakes use a caliper, caliper bracket, pads, rotor, and an electronic parking brake system, so the parking brake must be handled correctly before the caliper is removed.

Difficulty Level: Intermediate | Estimated Time: 2-3 hours

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⚠️ Safety & Precautions

• ⚠️ Work on a cool vehicle parked on level ground.
• ⚠️ Support your Tucson with jack stands. Never rely on a floor jack alone.
• ⚠️ Do not press the brake pedal while the caliper is removed.
• ⚠️ Your Tucson uses an electronic parking brake. The parking brake must be released before starting, and the rear caliper piston must not be forced backward without proper service-mode handling.
• ⚠️ Brake dust can be harmful. Wear a dust mask and avoid blowing dust with compressed air.
• ⚠️ Brake fluid damages paint. Keep the reservoir capped and clean spills immediately.

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🔧 Required Tools

You'll need the following tools for this repair:

• Floor jack (rated 2-ton minimum)
• Jack stands (rated 2-ton minimum)
• Wheel chocks
• 21mm lug nut socket
• Breaker bar 1/2-inch drive
• Torque wrench 1/2-inch drive
• 14mm socket
• 17mm wrench
• 17mm socket
• Phillips #3 screwdriver
• Impact screwdriver #3 Phillips (specialty)
• Rear brake caliper piston wind-back tool (specialty)
• Electronic parking brake service tool (specialty)
• OBD-II scan tool with EPB service mode (specialty)
• Brake cleaner aerosol
• Wire brush
• Small flathead screwdriver
• Rubber mallet
• C-clamp or brake hose hanger
• Bungee cord
• Brake fluid tester or clean turkey baster
• Nitrile gloves
• Safety glasses
• Dust mask

A torque wrench tightens bolts to the correct force so they are not too loose or too tight. An EPB service tool tells the electronic parking brake motor to retract safely.

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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 pad hardware kit - Qty: 1
• Brake lubricant - Qty: 1
• Brake cleaner aerosol - Qty: 1-2 cans
• DOT 4 brake fluid - Qty: 1 pint

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📋 Before You Begin

• 🅿️ Park your Tucson on a flat surface and place the transmission in Park.
• 🛑 Turn the electronic parking brake OFF before lifting the rear wheels.
• 🔋 Leave the battery connected because the electronic parking brake system needs power for service mode.
• 🧰 Use an OBD-II scan tool with EPB service mode and select the rear brake pad replacement or parking brake maintenance function.
• 📌 If your scan tool does not support EPB service mode, do not force the caliper piston back. This can damage the rear parking brake motor.
• 💧 Open the brake fluid reservoir cap before compressing pistons. If fluid is near the top, remove a small amount with a clean turkey baster.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Loosen the Rear Lug Nuts

• Use a 21mm lug nut socket and breaker bar 1/2-inch drive to loosen each rear lug nut about half a turn.
• Do this while the tires are still touching the ground so the wheels do not spin.
• Loosen only. Do not remove yet.

Step 2: Lift and Support the Rear of the Vehicle

• Place wheel chocks in front of the front tires.
• Use the floor jack (rated 2-ton minimum) at the rear center jacking point or approved side jacking point.
• Place jack stands (rated 2-ton minimum) under the approved rear support points.
• Lower your Tucson gently onto the jack stands and give the vehicle a light shake to confirm it is stable.

Step 3: Remove the Rear Wheels

• Use the 21mm lug nut socket to remove the rear lug nuts.
• Remove both rear wheels and place them flat under the vehicle as an added safety backup.

Step 4: Put the Electronic Parking Brake in Service Mode

• Connect the OBD-II scan tool with EPB service mode to the diagnostic port under the driver-side dash.
• Use the scan tool menu for Electronic Parking Brake > Maintenance Mode > Rear Pad Replacement > Retract.
• Wait until the scan tool confirms the rear parking brake motors are fully retracted.
• Turn the ignition OFF after the retract command completes, but leave the scan tool connected for later.

Step 5: Remove the Rear Caliper Slide Bolts

• Use a 14mm socket to remove the two rear caliper slide bolts.
• If the slide pin spins, hold it with a 17mm wrench while removing the bolt with the 14mm socket.
• A slide pin is the smooth pin that lets the caliper move in and out as the pads wear.

Step 6: Lift Off and Support the Caliper

• Gently lift the caliper off the rotor by hand.
• If it sticks, use a small flathead screwdriver to gently pry between the old pad and rotor.
• Hang the caliper with a bungee cord or C-clamp or brake hose hanger.
• Do not let the caliper hang by the rubber brake hose.

Step 7: Remove the Old Brake Pads and Hardware

• Pull the old pads out of the caliper bracket by hand.
• Use a small flathead screwdriver to remove the old metal pad clips from the bracket.
• The pad clips are small stainless pieces that help the pads slide smoothly and quietly.

Step 8: Remove the Caliper Bracket

• Use a 17mm socket and breaker bar 1/2-inch drive to remove the two rear caliper bracket bolts.
• Remove the caliper bracket from the rear knuckle.
• Set the bolts aside where they will stay clean.

Step 9: Remove the Rear Rotor Retaining Screw

• Use an impact screwdriver #3 Phillips (specialty) to loosen the rotor retaining screw.
• If the screw is not stuck, a Phillips #3 screwdriver may work.
• The retaining screw only holds the rotor in place during assembly; the wheel clamps the rotor when installed.

Step 10: Remove the Rear Rotor

• Pull the rotor straight off by hand.
• If it is stuck from rust, tap the rotor hat area with a rubber mallet.
• Do not hit the wheel studs.
• Rust can hold the rotor tightly.

Step 11: Clean the Hub Face

• Use a wire brush to clean rust from the wheel hub face.
• Spray the area with brake cleaner aerosol and wipe it dry.
• A clean hub helps the new rotor sit flat and prevents brake vibration.

Step 12: Install the New Rear Rotor

• Clean both sides of the new rotor with brake cleaner aerosol.
• Slide the rotor onto the hub by hand.
• Install the rotor retaining screw with a Phillips #3 screwdriver.
• Torque to 4-6 Nm (35-53 in-lbs).

Step 13: Clean and Prepare the Caliper Bracket

• Use a wire brush to clean the pad contact areas on the caliper bracket.
• Install the new brake pad hardware clips by hand.
• Apply a thin layer of brake lubricant where the pad ears touch the clips.
• Do not put lubricant on the pad friction material or rotor surface.

Step 14: Reinstall the Caliper Bracket

• Position the caliper bracket over the rotor.
• Install the bracket bolts by hand first to avoid cross-threading.
• Use a 17mm socket and torque wrench 1/2-inch drive to tighten the caliper bracket bolts.
• Torque to 79-98 Nm (58-72 ft-lbs).

Step 15: Compress the Rear Caliper Piston

• Use the rear brake caliper piston wind-back tool (specialty) to rotate and push the piston back into the caliper.
• Turn the piston slowly while applying light pressure.
• A wind-back tool turns the piston while pushing it inward, which is needed on many rear brake calipers.
• Watch the brake fluid reservoir while compressing the piston. Remove excess fluid with a clean turkey baster if it rises too high.

Step 16: Install the New Rear Brake Pads

• Slide the new brake pads into the caliper bracket by hand.
• Make sure the pads move freely in the clips.
• If they are tight, remove them and clean the bracket again with the wire brush.
• Pads should slide, not jam.

Step 17: Reinstall the Rear Caliper

• Place the caliper over the new pads and rotor by hand.
• Install the caliper slide bolts by hand first.
• Use a 14mm socket to tighten the slide bolts while holding the pin with a 17mm wrench if needed.
• Torque to 22-32 Nm (16-24 ft-lbs).

Step 18: Repeat on the Other Rear Side

• Repeat Steps 5 through 17 on the opposite rear wheel.
• Use the same tools and torque specifications.
• Always replace rear pads and rotors in pairs.

Step 19: Reinstall the Rear Wheels

• Install each wheel by hand.
• Thread the lug nuts by hand first.
• Use the 21mm lug nut socket to snug the lug nuts in a star pattern.

Step 20: Lower the Vehicle and Torque the Lug Nuts

• Use the floor jack (rated 2-ton minimum) to lift your Tucson slightly off the jack stands.
• Remove the jack stands (rated 2-ton minimum).
• Lower the vehicle until the tires touch the ground.
• Use the 21mm lug nut socket and torque wrench 1/2-inch drive to tighten the lug nuts in a star pattern.
• Torque to 107-127 Nm (79-94 ft-lbs).

Step 21: Exit EPB Service Mode

• Turn the ignition ON without starting the engine.
• Use the OBD-II scan tool with EPB service mode and select Electronic Parking Brake > Maintenance Mode > Rear Pad Replacement > Apply/Exit.
• Wait for the scan tool to confirm the parking brake motors have been initialized.
• Turn the ignition OFF, then disconnect the scan tool.

Step 22: Pump the Brake Pedal

• Sit in the driver seat and press the brake pedal slowly 5-10 times.
• The pedal should become firm before driving.
• If the pedal stays soft or sinks, do not drive the vehicle.

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✅ After Repair

• ✅ Check the brake fluid level and top off with DOT 4 brake fluid if needed.
• ✅ Start your Tucson and confirm the brake warning light and parking brake warning light turn off normally.
• ✅ Test the electronic parking brake several times while parked.
• ✅ Do a slow test drive in a safe area. Make several gentle stops from low speed.
• ✅ Bed in the new pads with 8-10 moderate stops from about 30 mph to 5 mph, allowing light cooling time between stops.
• ✅ Avoid hard braking for the first 200 miles unless it is an emergency.
• ✅ Recheck lug nut torque after 25-50 miles.

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💰 DIY vs Shop Cost

Shop Cost: $350-$650 (parts + labor)

DIY Cost: $120-$260 (parts only)

You Save: $230-$390 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 1.5-2.5 hours.

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