This procedure covers the replacement of the rear air spring/air bag assembly on a 2016-2024 Hyundai Tucson with 2.5L I4 AWD, including suspension component disconnection and reassembly.

Warnings

Tools required

Parts

• Rear air spring/air bag assembly × 1 — Use OEM specification
• Air line O-ring (if applicable) × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks in front of front wheels
3. If equipped with active air suspension, use the vehicle's onboard system to lower the suspension to its lowest setting and disable the air suspension system
4. Loosen rear wheel lug nuts while vehicle is still on ground
5. Raise rear of vehicle with floor jack and secure on jack stands at manufacturer-specified jacking points
6. Remove rear wheel completely

Procedure

1. 1

   Support the rear suspension
   Position a floor jack under the rear lower control arm or trailing arm near the wheel hub to support the suspension assembly. Raise jack just enough to take up the weight but not lift the vehicle further. This prevents the suspension from dropping when components are disconnected.
2. 2

   Disconnect air line (if equipped)
   Locate the air supply line connection at the top or bottom of the air spring. Press the release collar on the quick-connect fitting and pull the air line straight out. If the fitting is difficult to release, apply penetrating oil and wait 5 minutes. Inspect the O-ring on the air line and replace if damaged.
   ⚠Ensure air suspension system is fully depressurized before disconnecting. Listen for any escaping air and stop if pressure is detected.
3. 3

   Remove upper mounting hardware
   Access the upper air spring mount from inside the vehicle cargo area. Pull back the rear interior panel or access cover to expose the upper mounting nuts. Remove the mounting nuts securing the air spring to the strut tower using a socket and ratchet. Keep nuts organized for reinstallation.
   ℹ️Some models may require removal of cargo trim panels for access. Use plastic trim tools to avoid damage.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
4. 4

   Disconnect lower mounting point
   Locate the lower mounting bolt(s) securing the air spring to the lower control arm or axle assembly. Remove the mounting bolt(s) while supporting the air spring with one hand. The suspension should remain supported by the floor jack positioned earlier.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
5. 5

   Remove air spring assembly
   Carefully lower the floor jack slightly to create clearance. Guide the air spring assembly out from between the upper mount and lower suspension components. Maneuver the air spring out through the wheel well opening. Inspect the mounting surfaces on both upper and lower mounts for corrosion or damage.
6. 6

   Prepare new air spring
   Unpack the new air spring assembly and compare it to the old unit to verify correct application. Apply a light coat of soapy water or assembly lubricant to any rubber mounting bushings to ease installation. If the air line quick-connect fitting has a replaceable O-ring, install a new lubricated O-ring.
7. 7

   Install new air spring assembly
   Guide the new air spring into position through the wheel well opening. Align the upper mounting studs with the holes in the strut tower. You may need to raise or lower the floor jack supporting the suspension to achieve proper alignment. Ensure the air spring is oriented correctly with air line connection accessible.
8. 8

   Secure upper mounting
   From inside the cargo area, thread the upper mounting nuts onto the studs by hand. Tighten the mounting nuts to specification in a cross pattern to ensure even seating. Do not overtighten as this may damage the air spring mounting plate.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
9. 9

   Secure lower mounting
   Use the floor jack to align the lower mounting point of the air spring with the lower control arm or axle bracket. Install the lower mounting bolt(s) and tighten to specification. Ensure the air spring is not twisted or binding during installation.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
10. 10

    Reconnect air line
    Push the air line straight into the quick-connect fitting on the air spring until you hear and feel a positive click. Gently pull on the line to verify it is locked in place. Ensure the line is routed properly and not kinked or contacting any moving components or sharp edges.
11. 11

    Reinstall wheel and lower vehicle
    Reinstall the rear wheel and thread lug nuts by hand. Lower the vehicle from the jack stands until the wheel just contacts the ground but vehicle weight is still supported. Torque lug nuts to specification in a star pattern. Remove jack stands and fully lower vehicle to ground.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Reinstall any interior trim panels or access covers removed during upper mount access
2. If vehicle has active air suspension, reactivate the system through the vehicle controls or by cycling the ignition
3. Allow the air suspension system to pressurize fully before driving (typically 30-60 seconds after system activation)

Verification

• With vehicle on level ground, verify the rear suspension height is even side-to-side and matches the front-to-rear stance
• Start the vehicle and listen for any unusual air leaks from the air line connections
• If equipped with active suspension controls, cycle through all height settings to verify air spring operates correctly
• Perform a test drive over various road surfaces and verify ride quality is restored and no abnormal noises are present
• Check for any fault codes related to the air suspension system using an OBD-II scanner

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