2022-2023 Hyundai Tucson, Santa Fe, Santa Cruz Brake Judder TSB

Hyundai has issued Technical Service Bulletin (TSB) 23-BR-004H to address a brake judder condition that may affect certain 2022-2023 Hyundai Tucson (NX4A), Santa Cruz (NXT), Santa Fe (TMA), and Santa Fe Hybrid (TMA HEV) vehicles. This bulletin provides a comprehensive guide for technicians to inspect, service, and resolve the Hyundai brake judder issue. The TSB, dated November 2023, details procedures for brake inspection, resurfacing or replacement, and a crucial brake burnishing process.

Symptoms

Owners of affected vehicles may experience a Hyundai brake judder condition. This typically manifests as a vibration or pulsation felt through the brake pedal or steering wheel when applying the brakes. This sensation indicates an irregularity in the brake rotors, which can affect braking performance and driving comfort.

Diagnosis and Trigger Conditions

To diagnose the Hyundai brake judder, technicians will first confirm the presence of the judder. If confirmed, the front brake rotors will be inspected, with a critical step being the measurement of rotor thickness. The standard thickness for these brake discs is 30mm (1.18 inches), with a service limit of 28mm (1.10 inches). If the rotor thickness is below this service limit, replacement is necessary.

For accurate measurement, technicians are instructed to "remove all surface contamination and corrosion to ensure an accurate measurement." Measurements should be taken at "8 points (every 45 degrees)" around the rotor, specifically 5-10mm (0.2-0.4 inches) inboard from the outer edge. These measurements must be recorded on the repair order sheet.

Repair Procedure Summary

The repair process outlined in TSB 23-BR-004H involves several key steps:

1. Initial Inspection: Verify the presence of brake judder. If no judder is present, the TSB does not apply.
2. Rotor Thickness Inspection: Measure the thickness of both front brake rotors. If the thickness is above the 28mm service limit, the rotors can be resurfaced. If it is at or below the service limit, both front rotors must be replaced.
3. Resurfacing or Replacement:
   • If resurfacing, an on-car brake lathe is recommended. Technicians must measure rotor thickness both BEFORE and AFTER machining to ensure it remains within specification.
   • If replacement is necessary, new front brake discs will be installed.
4. Rotor Runout Inspection: With the brake rotors and calipers fully assembled, inspect the rotor runout. A dial indicator should be mounted on the brake rotor 5-10mm or 0.2-0.4 inches inboard of the outer edge, and the measurement recorded.
5. Cleaning and Tightening: Verify that the rotors are free of grease or other contamination, cleaning with brake cleaner if needed. All bolts must be tightened to the torque specification recommended in the vehicle shop manual.
6. Wheel Re-installation: When re-installing the wheels, lug nuts must be tightened in a star pattern to the specified torque to reduce the chance of runout.
7. Brake Burnishing Procedure: After installing machined or new rotors, a specific brake burnishing procedure must be performed.

Brake Burnishing Procedure

This critical step ensures proper seating of the brake pads to the rotors:

1. Drive the vehicle and accelerate to 50 mph. Apply the brakes using moderate force (approximately 0.3g deceleration rate) to slow the vehicle to 10 mph. This action should take approximately 6 seconds.
2. With as little cooling time as possible between braking events, repeat this procedure 10 times.

Required Tools and Parts

For this service, an on-car brake lathe, such as the PFM 9.0 or higher version by PRO-CUT, is recommended. This tool is available through Bosch (contact at 1-866-539-4248).

Replacement front brake discs are available under the following new part numbers:

• Tucson (NX4A): 51712-L0100QQH (replaces 51712-L0100)
• Santa Cruz (NXT), Santa Fe (TMA), Santa Fe Hybrid (TMA HEV): 51712-R5000QQH (replaces 51712-R5000)

Two discs are required for each service.

Important Warnings and Warranty Information

• Rotor Replacement: "If either rotor's thickness is under the service limit (before or after machining), replace both front rotors." This ensures optimal braking performance and safety.
• Part Return Policy: "Claim is subject to debit if the part is not returned." Incident parts are subject to callback through the Warranty Technical Center (WTC) parts return process.
• Persistent Judder: If the rotors are machined and burnished, but the judder is still present, the rotors may be replaced under warranty. Dealers must submit a campaign claim ending in “R0” for the disc machining and burnishing.
• Claim Submission: Claims should be submitted on the Claim Entry Screen as “Campaign” type. If a part needs replacement and is still under warranty, a separate claim should be submitted using the same repair order.
• Documentation: This TSB requires repair validation photos, including VIN, mileage, and repair validation photos as outlined in the Digital Documentation Policy. Clear photos of freshly resurfaced or new brake rotors (both left and right), with the last 6 digits of the VIN and the repair date on paper, must be uploaded to STUI.

Owner Action

If you experience a Hyundai brake judder in your 2022-2023 Hyundai Tucson, Santa Cruz, or Santa Fe, contact your authorized Hyundai dealer. Referencing TSB 23-BR-004H will help ensure they are aware of the specific procedure for diagnosis and repair. This service is typically covered under warranty if the vehicle meets the specified conditions.

NHTSA ID: 10248882