Complete disassembly, inspection, and rebuild of the 8-speed automatic transmission for 2016-2024 Hyundai Tucson 2.5L AWD, including internal component replacement and adjustment.

Warnings

Tools required

Parts

• Automatic transmission rebuild kit (includes clutches, steels, gaskets, seals) × 1 — Use OEM specification
• Torque converter (if damaged or contaminated) × 1 — Use OEM specification
• Transmission filter and gasket × 1 — Use OEM specification
• Valve body gasket set × 1 — Use OEM specification
• Pump seal and O-rings × 1 — Use OEM specification
• Input/output shaft seals × 1 — Use OEM specification
• Thrust washers and bearings (as needed) × 1 — Use OEM specification
• Solenoid pack (if diagnostics indicate failure) × 1 — Use OEM specification
• Transmission pan gasket × 1 — Use OEM specification
• Drain plug crush washer × 1 — Use OEM specification
• Transmission mounting bolts (if damaged) × 1 — Use OEM specification
• Transfer case adapter seals × 1 — Use OEM specification

Fluids

• Hyundai SP-IV-M ATF — 10 qt
• Transfer Case Fluid — 2.5 qt

Preparation

1. Obtain factory service manual for specific clutch clearance specifications and hydraulic pressure test procedures
2. Prepare clean workspace with adequate lighting and ventilation
3. Disconnect negative battery terminal and wait 3 minutes for airbag system to discharge
4. Raise vehicle on lift or securely support on jack stands at all four corners
5. Remove engine under covers and splash shields
6. Drain transmission fluid via drain plug, then remove pan for complete drainage
7. Drain transfer case fluid
8. Remove front wheels and front driveshaft from transfer case
9. Disconnect shifter cable, electrical connectors, cooler lines, and breather hose from transmission
10. Support engine with support bar or overhead hoist to prevent tilting when transmission is removed
11. Position transmission jack under transmission with proper adapter

Procedure

1. 1

   Remove transmission from vehicle
   Remove starter motor. Disconnect torque converter bolts through starter opening by rotating crankshaft. Remove rear engine mount if necessary for clearance. Remove transmission mounting bolts in sequence from outermost to innermost. Carefully separate transmission from engine, ensuring torque converter remains with transmission. Lower transmission on jack and move to clean workbench.
   Torque spec

   Flywheel Bolts95 Nm (70 lb-ft)

   Mounting Bolts61 Nm (45 lb-ft)
2. 2

   External disassembly and inspection
   Remove torque converter and inspect for cracks, wear, or metal contamination. Check stator one-way clutch operation. Remove valve body cover screws and carefully remove valve body assembly, noting position of manual valve. Remove external sensors, solenoid pack, and wiring harness. Remove transmission pan if not already removed. Inspect for metal debris, clutch material, or excessive sludge which indicates internal damage extent.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)

   Sensor Bolts11 Nm (8 lb-ft)

   Pan Bolts16 Nm (12 lb-ft)
3. 3

   Pump and input shaft removal
   Remove pump mounting bolts and carefully extract pump assembly with input shaft. Avoid damaging pump bushing or O-ring grooves. Inspect pump gears for scoring or excessive wear. Measure pump gear clearances with feeler gauges per factory specifications. Remove and inspect pump seal and bushing for wear.
4. 4

   Clutch pack and planetary gear disassembly
   Remove snap rings securing clutch drum assemblies. Carefully extract each clutch pack in order: forward clutch, direct clutch, low-reverse clutch, and intermediate clutch. Mark orientation of each component. Remove planetary gear sets and note thrust washer positions. Use dial indicator to check end play of each shaft before disassembly. Document all measurements for comparison during reassembly.
   ⚠Some clutch packs are under spring pressure. Use appropriate spring compressor before removing snap rings to prevent injury.
5. 5

   Disassemble and inspect clutch packs
   Separate each clutch pack on clean work surface. Remove snap rings, pressure plates, friction discs, and steel separator plates. Inspect friction discs for glazing, burning, or material separation. Measure friction disc thickness with micrometer and compare to service limits (typically 2.0-2.2mm minimum). Inspect steel plates for heat discoloration or warping. Check clutch springs and return springs for weakness or breakage. Inspect piston seals for hardening, cracking, or damage.
6. 6

   Case and shaft inspection
   Clean transmission case thoroughly with solvent and compressed air. Inspect all bearing bores, bushings, and valve body mounting surface for scoring or wear. Check case for cracks, especially around bolt holes and bearing pockets. Inspect all shafts for wear, scoring, or damage to splines. Measure shaft runout with dial indicator. Check all bearing surfaces and snap ring grooves. Replace any worn bushings using appropriate tools.
7. 7

   Measure and document critical clearances
   Use Plastigage to measure bearing clearances on all main shafts and planetary carrier bearings. Clearances should typically be 0.02-0.08mm; consult factory manual. Measure thrust washer thickness with micrometer. Check gear teeth for wear or damage. Measure planetary pinion end play. Document all measurements for comparison to factory specifications.
8. 8

   Clean and inspect valve body
   Disassemble valve body carefully, noting position and orientation of all valves, springs, and check balls. Clean all passages with solvent and compressed air. Inspect valve bores for scoring or varnish buildup. Check all valves for free movement in their bores without binding. Inspect springs for proper tension. Replace any worn or damaged components. Clean solenoid pack and test solenoid operation electrically if possible.
   ⚠Valve body contains many small springs and check balls. Work in contained area to prevent loss of components. Refer to factory diagram during disassembly.
9. 9

   Replace seals and soft parts
   Install new seals on all pistons using appropriate seal installation tools. Lubricate seals with ATF during installation. Replace all O-rings, gaskets, and thrust washers with new parts from rebuild kit. Install new pump seal and bushing if wear was evident. Replace input and output shaft seals. Ensure all sealing surfaces are clean and free of damage.
10. 10

    Reassemble clutch packs
    Assemble each clutch pack with new friction discs and reused steel plates (unless damaged). Soak new friction discs in Hyundai SP-IV-M ATF for 15 minutes before installation. Install components in correct order per rebuild kit instructions: dish plate, friction disc, steel plate pattern. Install pressure plate and secure with snap ring. Measure clutch pack clearance with feeler gauge between snap ring and pressure plate. Clearance should typically be 0.8-1.2mm; adjust with selective snap rings or backing plates as specified.
11. 11

    Install planetary gears and shafts
    Install thrust washers in correct positions with ATF to hold in place. Install planetary gear sets in proper order, ensuring all splines engage correctly. Install output shaft and check for proper rotation and end play. Install clutch drum assemblies in reverse order of removal. Install each snap ring and verify proper seating. Check each assembly for smooth rotation without binding.
    ℹ️Apply ATF to all moving parts during assembly to provide initial lubrication and prevent dry start damage.
12. 12

    Install pump assembly
    Install new O-rings on pump body and lubricate with ATF. Align pump with input shaft and case carefully. Tap gently with soft mallet if needed to seat fully. Install pump bolts and tighten in criss-cross pattern to specified torque. Verify pump rotates freely by turning input shaft. Check that input shaft end play is within specification using dial indicator.
13. 13

    Install valve body and solenoids
    Install new valve body gasket. Position valve body carefully, ensuring manual valve aligns with detent lever. Install valve body bolts finger tight, then torque in criss-cross pattern to specification. Install solenoid pack with new O-rings and torque mounting bolts. Connect internal wiring harness. Install all external sensors with new O-rings where applicable. Install new transmission filter.
    Torque spec

    Sensor Bolts11 Nm (8 lb-ft)
14. 14

    Install transmission pan and prepare for installation
    Clean pan and case mating surface thoroughly. Install new pan gasket or apply RTV sealant as specified. Install pan and torque bolts in criss-cross pattern starting from center. Install drain plug with new crush washer. Install torque converter, ensuring it is fully seated with at least three engagement clicks. Measure torque converter depth to ensure proper seating (should be recessed approximately 10-15mm from bell housing face).
    Torque spec

    Pan Bolts16 Nm (12 lb-ft)

    Transmission Drain Plug30 Nm (22 lb-ft)
15. 15

    Install transmission to vehicle
    Raise transmission into position using transmission jack. Align torque converter with flexplate, rotating crankshaft as needed. Install transmission mounting bolts and torque in sequence: smaller mounting bolts to 27 Nm, larger mounting bolts to 61 Nm. Install torque converter to flexplate bolts through starter opening, torquing to 95 Nm in star pattern. Install starter motor. Reconnect all electrical connectors, cooler lines, shifter cable, and breather hose. Install transfer case if removed. Connect front driveshaft. Reinstall any removed mounts and supports.
    Torque spec

    Mounting Bolts61 Nm (45 lb-ft)

    Flywheel Bolts95 Nm (70 lb-ft)

Reassembly

1. Reinstall front driveshaft with new self-locking bolts if applicable
2. Refill transfer case with 2.5 quarts of transfer case fluid
3. Fill transmission with approximately 4-5 quarts of Hyundai SP-IV-M ATF initially (additional fluid added during procedure)
4. Reinstall front wheels and torque lug nuts to specification
5. Reinstall under covers and splash shields
6. Reconnect negative battery terminal
7. Perform transmission fluid level procedure: start engine, cycle through all gear positions pausing 3 seconds in each, return to Park, check level with engine running at operating temperature (70-80°C fluid temp). Add fluid as needed to bring to proper level on dipstick or fill plug
8. Clear any transmission fault codes with scan tool
9. Perform transmission adaptation/learning procedure using factory scan tool if required

Verification

• Start engine and verify no fluid leaks from pan, cooler lines, or case seams
• With parking brake applied, shift through all gears and verify smooth engagement in each position
• Test drive vehicle and verify all gear changes occur smoothly without slipping, flaring, or harsh engagement
• Verify transmission shifts at appropriate speeds and responds correctly to throttle input
• Check for abnormal noises, vibrations, or delayed engagement
• Recheck fluid level after test drive with transmission at operating temperature
• Scan for fault codes and verify no transmission-related codes are present
• Monitor transmission fluid temperature during test drive; should reach 70-80°C and stabilize
• Verify proper AWD operation if equipped by confirming power delivery to front wheels during acceleration
• Schedule follow-up fluid and filter change at 500-1000 miles to remove any residual debris from break-in period

More procedures for this vehicle