If your Hyundai Santa Fe is making awful shuddering noises when you hit the brakes but you know that the brake pads are in good shape, then it's probably time to buy new rotors. Rotors don't need to be changed often, but if they get warped or scratched and can't be resurfaced, then it's time to replace them.
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Raise your Hyundai Santa Fe using jacks and jack stands. Be sure to block the wheels to keep your SUV from rolling while you work. Loosen the lug nuts on the first tire and then remove the tire from the wheel hub.
Apply the brake while removing the split pin, castle nut and washer from the hub. Next, remove the caliper mounting bolts with a socket wrench or air ratchet and then slide the caliper off of the brake disc. Use mechanic's wire to suspend the caliper and connected brake line out of the way while you work. Be careful not to let the brake line get disconnected from the caliper.
Remove the wheel speed sensor from the knuckle and then disconnect the tie rod end ball joint from the knuckle as well. Next, unfasten the split pin and castle nut and disconnect the ball joint.
Unscrew the lower arm ball joint mounting bolts and remove the strut lower arm mounting bolts. Now you can remove the hub and the knuckle assembly which frees up the brake disc (rotor). Pull off the old rotor and set it aside. Clean the area around the hub with a damp cloth.
Install the new rotor onto the hub and tighten the holding screws. Use a torque wrench to replace the knuckle assembly and hub, lower arm mounting bolts, ball joint mounting bolts and reconnect the ball joint.
Fasten the castle nut and split pin. Replace the tie rod end ball joint to the knuckle and put the wheel speed sensor back into position. Slide the caliper back into place and tighten the caliper mounting bolts. Put the washer, castle nut and split pin back. Put the wheel assembly and tire back together.
Repeat this process for each additional rotor. Replace all of the rotors at once, or at least the front or rear end pair. After the installation, lower the SUV, tighten and torque the lug nuts on each tire. Test drive your Santa Fe to make sure that everything is working properly.