2020-2022 Kia Telluride Brake Rotor Minimum Thickness and When to Replace

By Core Brake Parts Tech Team — Circleville, OH warehouse

On a 2020-2022 Kia Telluride, the front rotors start at 30 mm thick and should be replaced once they wear to 28 mm. The rear rotors start at about 11 mm and are done at 9 mm. Those are the discard figures published for replacement rotors that fit this vehicle, but the number cast or stamped on the rotor you actually have on the vehicle is the one that rules.

That leaves only 2 mm of usable wear on each axle, which is less than most owners expect. Here is how the Telluride's brakes are laid out, how to measure correctly, and how to decide between keeping, resurfacing or replacing your rotors.

Telluride Rotor Specs at a Glance

The 2020-2022 Telluride uses a large vented rotor up front and a solid rotor in the rear. The same rotors are listed for the Hyundai Palisade, which shares the platform, so a Palisade-labelled rotor with matching specs is the same part. The figures below come from the published spec sheets of replacement rotors listed for the 2020-2022 Telluride.

The 2 mm figure is total wear across both faces of the rotor, not per side. On a rotor that is 1 mm over the limit when you measure it, there is not enough material left to resurface it and still stay above discard, so on this vehicle a cut is rarely worth paying for.

Where to Find the Minimum Thickness on Your Rotor

Every rotor carries its own minimum, marked as MIN TH (or MIN THK) followed by a value in millimetres. On most rotors it is cast into the hat (the raised center section) or stamped on the outer edge of the friction ring. Brembo's maintenance guidance says to replace a disc if any measurement falls below its MIN TH value.

If you have aftermarket rotors installed, read the number on the rotor rather than trusting a chart. Drilled, slotted and performance rotors can have a different nominal thickness or discard figure from the standard replacement part, and the marking on the part is the manufacturer's limit for that design.

How to Measure Telluride Rotors Correctly

Measure with a micrometer or a vernier caliper, never with a ruler or by eye. The outer edge of a used rotor has a lip of unworn metal that the pads never touch, so the jaws of the tool need to reach in onto the swept area where the pads ride.

1. Safely raise and support the vehicle and remove the wheel.
2. Clean rust and dirt off the friction face where you will measure.
3. Measure at a minimum of four points around the rotor, as Brembo recommends, reaching in past the outer lip.
4. Use the lowest reading as the rotor's thickness. A rotor is only as thick as its thinnest spot.
5. Compare the lowest reading with the MIN TH marking. If it is at or below the mark, the rotor is done.
6. If thickness varies noticeably from one point to the next, the rotor has thickness variation, which is the usual cause of a pulsing pedal even when the rotor is still above minimum.

Brembo also advises replacing discs on both sides of the axle, even if only one has fallen below the limit. Mixing a new rotor with a worn one on the same axle causes uneven braking and a pull.

Signs Your Telluride Rotors Need Replacing

Thickness is the hard limit, but rotors often need replacing before they get there. Look for these:

• Pulsing brake pedal or steering wheel shake under braking, usually from thickness variation or uneven pad deposits on the front rotors. The Telluride is a heavy three-row SUV, so the fronts do most of the work and show this first.
• A deep lip at the outer edge you can catch with a fingernail, which tells you a lot of material has worn away.
• Grooves or scoring from pads that wore down to their backing plates.
• Blue or dark heat spots and cracks, which mean the rotor has overheated, often from towing or long descents.
• Heavy rust on the rear rotors, especially on vehicles that sit or see road salt. The solid rear rotors do less work and can rust on the face rather than wear.
• Pads due for replacement on a rotor that is close to minimum. With only 2 mm of wear available, a rotor that is near the mark will not last through another set of pads.

Brembo's general rule is that discs are typically replaced every other time the pads are replaced. On the Telluride, with its small wear allowance, many owners find a new set of rotors with every pad change is the better value, because resurfacing is usually off the table.

Front vs Rear: What Is Different on This Vehicle

The front brakes carry most of the stopping load, so the front rotors and pads wear faster and are usually the first job. The front rotor is vented, with cooling vanes between its two faces, which is why it is so much thicker than the rear.

The rear brakes use a solid rotor and an electronic parking brake (EPB). On the Telluride the parking brake is applied by a motor at the rear caliper rather than a cable. A 2019 Kia service bulletin (SA381) for early 2020 Telluride vehicles covers the EPB connector located behind the left rear wheel area, which tells you that wiring runs right where you will be working. Before replacing rear pads or rotors, the EPB has to be put into service or maintenance mode with a scan tool or the procedure in the factory service information, so the caliper piston can be retracted. Forcing the piston back with the motor engaged can damage the actuator.

Unplug the EPB connector only when the service procedure calls for it, keep it clean, and make sure it locks fully when you reconnect it. The bulletin's own check is a pull test on that connector.

What to Replace Along With the Rotors

New rotors need fresh pads. Old pads are worn to the shape of the old rotor faces and will not bed in properly on a flat new surface, which can bring back noise and vibration. While the caliper is off, also plan on:

• New brake pads for the same axle. Ceramic brake pads are a good daily-driver choice for low dust and quiet operation.
• New abutment clips and pad hardware from a brake hardware kit, plus fresh caliper slide pin grease.
• Cleaning the hub face of rust so the new rotor sits flat. Rust trapped between hub and rotor causes runout and a pulsation that returns within a few thousand miles.
• Torquing the lug nuts in a star pattern to the value in the owner's manual, not with an impact gun at full power.
• Bedding in the new pads and rotors with a series of moderate stops before any hard braking.

For the rear axle, a matched kit takes the guesswork out of pairing parts. Our 2020-2022 Kia Telluride rear brake kit from R1 Concepts includes rotors and pads made for this vehicle. You can also browse all replacement brake rotors to find the front set.

How Hard Is the Job?

A front rotor and pad replacement on the Telluride is a straightforward job for someone with basic tools, a torque wrench, a jack and stands. The caliper bracket comes off to remove the rotor, and the bracket bolts are torqued to the factory value on reassembly. The fronts are heavy, so take care when lifting them off the hub.

The rears add one step: the electronic parking brake service mode. If you do not have a scan tool that can retract the EPB, the rear job is better left to a shop. Either way, measure the rotors first. A five-minute check with a micrometer tells you whether you are buying pads only or pads and rotors.

Frequently Asked Questions

What is the minimum front rotor thickness on a 2020-2022 Kia Telluride?

Replacement front rotors listed for the 2020-2022 Telluride are 30 mm thick new with a 28 mm discard thickness. Always confirm against the MIN TH marking on the rotor installed on your vehicle.

What is the minimum rear rotor thickness?

The rear rotor is a solid 305 mm disc about 11 mm thick new, with a published discard thickness of 9 mm from two different rotor manufacturers.

Can Telluride rotors be resurfaced?

Only if the rotor will still be above its minimum after the cut. With about 2 mm of wear allowed in total, most used Telluride rotors do not have enough material left, so replacement is usually the better choice.

Do Hyundai Palisade rotors fit the Kia Telluride?

The same replacement rotors are listed for both the Telluride and the Palisade of the same years, since they share a platform. Check the part's fitment for your exact year before ordering.

Do I need to replace rotors in pairs?

Yes. Brembo's guidance is to replace both discs on the axle even if only one is below the limit, so braking stays even side to side.

Why do I need a scan tool for the rear brakes?

The Telluride has an electronic parking brake at the rear calipers. It must be put into service mode before the rear caliper pistons can be retracted for new pads and rotors.

Sources

1. 1A Auto - TRQ front brake rotor set for 2020-2024 Kia Telluride and Hyundai Palisade - front rotor 340 mm diameter, 30 mm nominal, 28 mm discard thickness, vented, 69 mm center hole
2. Dynamic Friction 604-03060 rear rotor specifications - rear rotor 305 mm, 11 mm nominal, 9 mm discard, solid, fits 2020-2025 Telluride and Palisade
3. PowerStop JBR1778SCR rear rotor specifications - rear rotor 304.85 mm, 11.05 mm nominal, 9.00 mm discard, solid, Telluride fitment
4. Brembo - Minimum brake disc thickness - MIN TH marking, measure at four points, use lowest reading, replace in pairs, discs typically every other pad change
5. Kia TSB SA381 (via NHTSA) - Telluride EPB connector inspection - 2020MY Telluride has an electronic parking brake, connector behind the left rear wheel area