This procedure covers the removal and replacement of the rear ABS wheel speed sensor on a 2016-2024 Hyundai Tucson with 2.5L I4 AWD engine.

Warnings

Tools required

Parts

• Rear ABS wheel speed sensor × 1 — Use OEM specification (Hyundai/Kia 95680-series)

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock the front wheels to prevent rolling
3. Loosen rear wheel lug nuts while vehicle is on the ground
4. Raise rear of vehicle and support securely on jack stands
5. Remove the rear wheel on the affected side

Procedure

1. 1

   Locate the rear ABS sensor
   The rear ABS wheel speed sensor is mounted on the rear knuckle, near the brake rotor backing plate. The sensor wire routes up through clips along the trailing arm and connects to the main harness near the rear suspension tower.
2. 2

   Disconnect the sensor electrical connector
   Follow the sensor wire from the sensor to the electrical connector located near the rear suspension or underbody. Press the connector release tab and carefully separate the connector halves. If connector is corroded or difficult to release, gently work it free without damaging the locking tab.
3. 3

   Release the sensor wire from routing clips
   Carefully release the sensor wire from any clips or brackets along its routing path from the sensor to the connector. Note the exact routing for reinstallation. Use a flathead screwdriver or trim tool if needed to gently pry clips open without breaking them.
   ⚠The wire routing clips can be brittle - work carefully to avoid breaking them
4. 4

   Remove the ABS sensor mounting bolt
   Using a 10mm socket, remove the single bolt securing the ABS sensor to the rear knuckle. The bolt may be corroded or have threadlocker compound. If stuck, apply penetrating oil and allow it to soak before attempting removal again.
5. 5

   Remove the ABS sensor from the knuckle
   Carefully pull the sensor straight out of its bore in the knuckle. If the sensor is stuck due to corrosion, gently twist while pulling. Do not pry against the sensor body as this can crack the plastic housing. If severely stuck, apply penetrating oil around the sensor body and allow to soak for 15-20 minutes.
   ⚠Do not damage the sensor bore in the knuckle - excessive force can crack the casting
6. 6

   Clean the sensor mounting bore
   Use a wire brush and clean shop rag to thoroughly clean the sensor mounting bore in the knuckle. Remove any dirt, rust, or debris. The bore must be clean for proper sensor installation and to ensure correct air gap to the tone ring.
7. 7

   Prepare the new sensor for installation
   Inspect the new sensor to ensure the o-ring (if equipped) is properly seated. Apply a thin coat of dielectric grease to the sensor body where it enters the knuckle bore. Do not apply grease to the sensor tip itself.
8. 8

   Install the new ABS sensor
   Carefully insert the new sensor straight into the mounting bore in the knuckle. Push firmly until the sensor is fully seated with the mounting flange flush against the knuckle surface. Align the bolt hole.
9. 9

   Install and torque the sensor mounting bolt
   Install the ABS sensor mounting bolt and tighten by hand initially. Using a torque wrench, tighten the bolt to exactly 10.0 Nm (7.0 lb-ft). This torque is critical - overtightening can damage the sensor or crack the mounting boss.
   ⚠Do not exceed the specified torque - this is a low-torque fastener
   Torque spec

   ABS Sensor Bolt10 Nm (7 lb-ft)
10. 10

    Route and secure the sensor wire
    Route the sensor wire following the original path noted during removal. Secure the wire in all original clips and brackets. Ensure the wire has adequate slack and is not stretched, kinked, or routed where it can contact moving parts or hot exhaust components.
11. 11

    Reconnect the electrical connector
    Connect the sensor electrical connector to the vehicle harness connector. Push together until you hear or feel a positive click indicating the locking tab has engaged. Gently tug on the connection to verify it is locked.
12. 12

    Reinstall the wheel
    Reinstall the rear wheel, threading the lug nuts on by hand. Tighten lug nuts in a star pattern to proper torque specification after lowering the vehicle.
13. 13

    Lower vehicle and torque lug nuts
    Lower the vehicle to the ground. Using a torque wrench, tighten the wheel lug nuts to 136.0 Nm (100 lb-ft) in a star pattern to ensure even seating of the wheel.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Ensure sensor wire is properly routed and secured in all clips with adequate slack
2. Verify electrical connector is fully locked and sealed
3. Check that sensor mounting bolt is torqued correctly - do not overtighten

Verification

• Start the engine and verify the ABS warning light extinguishes after initial bulb check
• Drive the vehicle at speeds above 10 mph (15 km/h) to allow the ABS system to initialize the new sensor
• Use an OBD-II scanner to verify no ABS codes are present and that the new sensor is providing a signal
• Perform a test stop from moderate speed to confirm ABS system operates normally if equipped with scan tool capable of monitoring wheel speed sensor data

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