🔧 Tucson - Rear Brake Pad & Rotor Replacement

This repair replaces the rear brake pads and brake rotors on your Tucson. The rear parking brake is a mechanical drum-in-hat style, meaning small parking brake shoes sit inside the rear rotor hat.

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

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⚠️ Safety & Precautions

• ⚠️ Work on a cool brake system only. Hot rotors and calipers can burn you.
• ⚠️ Support your Tucson with jack stands. Never rely on a floor jack alone.
• ⚠️ Do not press the brake pedal while the rear caliper is removed.
• ⚠️ Release the parking brake before removing the rear rotors.
• ⚠️ Brake dust is harmful. Avoid blowing it with compressed air.
• ⚠️ If the brake pedal feels soft after repair, do not drive until corrected.

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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
• Ratchet wrench 3/8-inch drive
• 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 bit
• Brake caliper piston compressor tool
• Wire brush
• Brake parts cleaning spray
• Brake caliper hanger hook
• Small flat-blade screwdriver
• Rubber mallet
• 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 - Qty: 1
• Brake lubricant - Qty: 1
• Brake parts cleaning spray - Qty: 1

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📋 Before You Begin

• 🅿️ Park your Tucson on level ground.
• 🧱 Place wheel chocks in front of the front tires.
• 🔓 Release the parking brake completely before lifting the rear.
• 🧰 Loosen the rear lug nuts slightly before raising the vehicle.
• 📘 A caliper is the clamp that squeezes the brake pads against the rotor.
• 📘 A rotor is the round metal disc the brake pads grip to stop the vehicle.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Loosen Rear Lug Nuts

• Use the 21mm lug nut socket and breaker bar 1/2-inch drive to loosen each rear lug nut about half a turn.
• Do not remove the lug nuts yet.
• Loosen while tires still touch ground.

Step 2: Raise and Support the Rear

• Use the floor jack rated 2-ton minimum to lift the rear of your Tucson at the rear center jacking point or approved rear lift area.
• Place jack stands rated 2-ton minimum under the rear side pinch welds or approved support points.
• Gently lower the vehicle onto the jack stands.
• Keep the floor jack rated 2-ton minimum lightly touching the lift point as backup.

Step 3: Remove Rear Wheels

• Use the 21mm lug nut socket and ratchet wrench 3/8-inch drive to remove the loosened lug nuts.
• Remove both rear wheels and place them flat under the vehicle edge as an extra safety backup.

Step 4: Remove the Rear Caliper

• Use the 14mm socket and ratchet wrench 3/8-inch drive to remove the two rear caliper slide pin bolts.
• If the slide pin spins, hold it with the 17mm wrench while removing the bolt with the 14mm socket.
• Lift the caliper off the brake pads.
• Hang the caliper with the brake caliper hanger hook.
• Do not let the caliper hang by the brake hose.

Step 5: Remove the Old Brake Pads

• Slide the old inner and outer brake pads out of the caliper bracket by hand.
• Use the small flat-blade screwdriver only if the pads are stuck.
• Remove the old stainless pad clips from the bracket by hand or with the small flat-blade screwdriver.

Step 6: Remove the Caliper Bracket

• Use the 17mm socket and breaker bar 1/2-inch drive to remove the two rear caliper bracket bolts.
• Remove the caliper bracket from the knuckle.
• Set the bracket on a clean work surface.

Step 7: Remove the Rear Rotor

• Use the Phillips #3 screwdriver or impact screwdriver #3 Phillips bit to remove the rotor retaining screw if equipped.
• Pull the rotor straight off the hub.
• If the rotor is stuck, tap the rotor hat with the rubber mallet.
• If the rotor still will not move, make sure the parking brake is fully released.
• The parking brake shoes sit inside the rotor hat, so avoid forcing the rotor off at an angle.

Step 8: Clean the Hub and Bracket

• Use the wire brush to clean rust from the wheel hub face.
• Use brake parts cleaning spray to clean the hub and caliper bracket areas.
• Use the wire brush to clean the pad contact areas on the caliper bracket.
• Clean metal prevents brake vibration.

Step 9: Install the New Rotor

• Spray both sides of the new rotor with brake parts cleaning spray to remove protective oil.
• Slide the new rear rotor onto the hub by hand.
• If equipped, install the rotor retaining screw with the Phillips #3 screwdriver.
• Torque rotor retaining screw snug only, approximately 4-6 Nm (35-53 in-lbs).

Step 10: Reinstall the Caliper Bracket

• Position the caliper bracket over the rotor.
• Thread the two bracket bolts by hand first to prevent cross-threading.
• Use the 17mm socket and torque wrench 1/2-inch drive to tighten the bracket bolts.
• Torque to 78-98 Nm (58-72 ft-lbs).

Step 11: Install New Brake Hardware and Pads

• Install the new brake pad clips from the rear brake hardware kit into the caliper bracket by hand.
• Apply a thin layer of brake lubricant to the pad ears where they touch the clips.
• Do not put lubricant on the pad friction surface or rotor face.
• Slide the new inner and outer brake pads into the caliper bracket by hand.
• The pad ears are the small tabs at each end of the brake pad backing plate.

Step 12: Compress the Rear Caliper Piston

• Open the hood and check the brake fluid reservoir level.
• Use the brake caliper piston compressor tool to slowly press the rear caliper piston fully back into the caliper.
• Watch the brake fluid reservoir while compressing the piston.
• If the fluid rises near the top, remove a small amount with a clean suction tool if available.
• A caliper piston is the round part that pushes the inner brake pad.

Step 13: Reinstall the Rear Caliper

• Place the caliper over the new brake pads.
• Thread the two caliper slide pin bolts by hand.
• Use the 14mm socket and torque wrench 1/2-inch drive to tighten the caliper slide pin bolts.
• If the slide pin spins, hold it with the 17mm wrench.
• Torque to 22-32 Nm (16-24 ft-lbs).

Step 14: Repeat on the Other Side

• Repeat Steps 4 through 13 on the other rear wheel using the same tools.
• Always replace rear pads and rotors as a left-and-right pair.

Step 15: Reinstall Rear Wheels

• Install each rear wheel by hand.
• Thread all lug nuts by hand first.
• Use the 21mm lug nut socket and ratchet wrench 3/8-inch drive to snug the lug nuts in a star pattern.

Step 16: Lower Vehicle and Torque Lug Nuts

• Use the floor jack rated 2-ton minimum to raise the rear slightly off the jack stands.
• Remove the jack stands rated 2-ton minimum.
• Lower your Tucson until the tires just 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 88-107 Nm (65-79 ft-lbs).

Step 17: Pump the Brake Pedal

• Sit in the driver seat and press the brake pedal slowly several times.
• The pedal should become firm before you move the vehicle.
• This seats the caliper pistons against the new pads.

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✅ After Repair

• ✅ Check the brake fluid level and top off only if needed with the correct brake fluid listed on the reservoir cap.
• ✅ Start your Tucson and press the brake pedal again. It should feel firm.
• ✅ Reapply and release the parking brake several times to confirm normal operation.
• ✅ Test drive slowly in a safe area before driving in traffic.
• ✅ Bed in the new pads with several gentle stops from 30 mph to 5 mph. Avoid hard braking for the first 100 miles.
• ✅ Recheck lug nut torque after the first short drive.

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💰 DIY vs Shop Cost

Shop Cost: $350-$550 (parts + labor)

DIY Cost: $120-$230 (parts only)

You Save: $230-$320 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 1.5-2.0 hours.

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🎯 Ready to get started?

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