Complete removal and reinstallation of the 8-speed automatic transmission on a 2016-2024 Hyundai Tucson with 2.5L I4 engine and AWD, including driveshaft disconnection, transfer case separation, and fluid refill.

Warnings

Tools required

Parts

• Transmission drain plug crush washer × 1 — Use OEM specification
• Transmission fluid filter × 1 — Use OEM specification
• Transmission oil pan gasket × 1 — Use OEM specification
• Driveshaft flange bolts (if reuse not recommended) × 6 — Use OEM specification
• Transfer case gasket or sealant × 1 — Use OEM specification

Fluids

• Hyundai SP-IV-M ATF — 10 qt
• Transfer Case Fluid — 2.5 qt
• 75W-90 GL-5 Gear Oil (front differential) — 1.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery terminal and secure cable away from battery post
3. Raise vehicle on lift or with floor jack and support securely on jack stands at all four corners
4. Remove engine splash shield and underbody panels for access
5. Remove front wheels to access front axle components if needed for clearance
6. Allow transmission to cool if vehicle was recently driven
7. Place drain pan under transmission
8. Take photos of all electrical connector positions and routing for reference during reinstallation

Procedure

1. 1

   Drain transmission and transfer case fluids
   Remove transmission drain plug using appropriate socket and drain fluid completely into drain pan. Install new crush washer on drain plug and reinstall drain plug to specified torque. Move drain pan to transfer case drain location and drain transfer case fluid. If servicing internal filter, remove transmission pan bolts in criss-cross pattern, drop pan, and replace filter and gasket.
   Torque spec

   Transmission Drain Plug30 Nm (22 lb-ft)

   Pan Bolts16 Nm (12 lb-ft)
2. 2

   Disconnect electrical connectors and shift cable
   Disconnect all electrical connectors from transmission including: vehicle speed sensor, input/output speed sensors, shift solenoid connector, and transmission range sensor. Remove shift cable by prying cable end from transmission lever, then removing cable bracket retaining bolts. Label all connectors with tape for correct reassembly.
   Torque spec

   Sensor Bolts11 Nm (8 lb-ft)
3. 3

   Remove front driveshaft and disconnect front axles
   Mark front driveshaft-to-transfer case flange orientation for proper reinstallation. Remove driveshaft flange bolts and support driveshaft, then slide forward to disconnect from transfer case. Support front axle shafts and remove axle shaft retaining nuts/bolts from transmission. Carefully pull axle shafts from transmission and secure out of work area. Plug transmission openings to prevent fluid loss and contamination.
4. 4

   Remove rear driveshaft
   Mark rear driveshaft-to-transfer case and rear differential flanges for proper alignment during reinstallation. Remove rear driveshaft flange bolts at transfer case. Support driveshaft and remove rear flange bolts at differential. Remove complete rear driveshaft assembly and store safely away from work area.
5. 5

   Disconnect cooler lines and breather hose
   Place drain pan under transmission cooler line connections. Using appropriate line wrench, disconnect transmission cooler lines from transmission housing. Cap or plug lines and transmission ports immediately to prevent contamination. Disconnect breather hose from top of transmission. Be prepared for residual fluid drainage.
   ⚠Cooler lines contain residual ATF under slight pressure. Have rags ready to catch spillage.
6. 6

   Support engine and remove crossmember
   Install engine support bar across engine bay or use engine hoist to support engine weight from above. Ensure engine is securely supported and stable. Remove transmission crossmember mounting bolts and carefully lower and remove crossmember. Verify engine remains stable and properly supported before proceeding.
   ⚠️Never proceed without proper engine support. Engine can drop and cause severe injury or damage.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
7. 7

   Remove starter motor
   Disconnect starter electrical connections (battery cable and solenoid wire). Remove starter mounting bolts and carefully extract starter motor from bellhousing. Store starter in safe location away from transmission removal area. Inspect starter gear teeth and replace if damaged.
8. 8

   Support transmission and remove bellhousing bolts
   Position transmission jack under transmission oil pan using proper adapter to distribute load. Secure transmission to jack using safety chains or straps. Raise jack slightly to take weight off mounts. Remove all bellhousing-to-engine bolts, working from top to bottom. Keep bolts organized by location as they may be different lengths. Remove any remaining brackets or ground straps attached to bellhousing.
   Torque spec

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

   Separate transmission from engine
   Double-check all electrical connectors, cooler lines, and mounting bolts are disconnected. Slowly pull transmission straight back away from engine using transmission jack. Guide transmission carefully to avoid damaging input shaft, torque converter, or clutch housing. Once input shaft clears bellhousing, angle transmission nose down slightly and continue pulling rearward. Keep torque converter secured to transmission (use strap or wire if necessary to prevent it from sliding off).
   ⚠️Torque converter can slide off input shaft during removal. Secure converter to transmission to prevent it from falling.
   ⚠Transmission input shaft must clear engine block precisely. Do not force or pry against aluminum transmission case.
10. 10

    Lower and remove transmission assembly
    Once transmission is clear of engine, carefully lower transmission jack and maneuver transmission assembly out from under vehicle. Be aware of weight distribution changes as transmission is lowered. Transfer case remains attached to transmission during removal. Place transmission on appropriate stand or secure work surface for service or replacement.
11. 11

    Inspect and prepare for installation
    Inspect engine flexplate for cracks, heat damage, or damaged ring gear teeth. Verify torque converter is fully seated in transmission pump (typically 3 engagement points with specific depth measurement). Measure torque converter depth from bellhousing mating surface to converter lugs - should be approximately 10-15mm recessed. Clean all mating surfaces on engine block and transmission bellhousing. Apply small amount of high-temp grease to torque converter pilot and input shaft splines. Verify all dowel pins are present in engine block.
    ⚠Improperly seated torque converter will cause catastrophic transmission failure upon startup. Verify converter engagement by measuring recess depth and checking for three distinct clicks during installation.
12. 12

    Install transmission onto engine
    Position transmission on jack and raise into position, aligning with engine. Ensure torque converter remains fully seated in pump. Carefully guide transmission forward, aligning input shaft with engine crankshaft pilot bearing. Rotate transmission or engine slightly if needed for spline alignment. Once started, push transmission forward until bellhousing contacts engine block evenly. Transmission should slide on relatively easily - resistance indicates misalignment. Install upper bellhousing bolts finger-tight first to hold alignment.
13. 13

    Install and torque bellhousing bolts
    Install all bellhousing-to-engine mounting bolts and tighten progressively in star pattern. Torque small mounting bolts (10mm) to 27 Nm (20 lb-ft) and large mounting bolts (14mm or larger) to 61 Nm (45 lb-ft). Reinstall any brackets or ground straps removed during disassembly. Verify transmission is seated flush against engine block before final torquing.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
14. 14

    Install torque converter bolts
    Rotate crankshaft to access each torque converter-to-flexplate bolt location through starter motor opening. Install all flywheel/flexplate bolts and tighten in star pattern to 95 Nm (70 lb-ft). These are often torque-to-yield (TTY) bolts - use new bolts if specified by manufacturer. Rotate engine through two complete revolutions to verify free rotation and proper converter alignment.
    ℹ️Verify flywheel bolts are TTY type and replace if required. Reusing TTY bolts can result in bolt failure and transmission damage.
    Torque spec

    Flywheel Bolts95 Nm (70 lb-ft)
15. 15

    Reinstall starter and crossmember
    Install starter motor into bellhousing and torque mounting bolts to specification. Reconnect starter electrical connections (battery cable and solenoid wire). Position transmission crossmember and install mounting bolts, torquing to specification. Remove engine support fixture once crossmember is secured and transmission weight is transferred to mounts.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
16. 16

    Reconnect cooler lines, axles, and driveshafts
    Remove plugs from transmission and cooler lines. Connect transmission cooler lines and tighten fittings to specification using line wrench. Install front axle shafts into transmission, ensuring they fully engage and lock into place. Reinstall axle retaining hardware. Install rear driveshaft aligning marks made during removal and torque flange bolts to specification. Install front driveshaft to transfer case, aligning marks and torquing bolts to specification.
17. 17

    Reconnect electrical and shift cable
    Reconnect all transmission electrical connectors in their original positions using reference photos. Verify positive engagement of each connector. Install shift cable to transmission lever and bracket, ensuring cable moves freely through full range. Adjust shift cable if necessary per manufacturer procedure.
    Torque spec

    Sensor Bolts11 Nm (8 lb-ft)
18. 18

    Refill transmission and transfer case
    Using fluid pump or fill bottle, add Hyundai SP-IV-M ATF through transmission dipstick tube or fill port. Add approximately 5-6 quarts initially. Refill transfer case with 2.5 quarts of transfer case fluid through fill plug. If front differential was drained, refill with 1.5 quarts 75W-90 GL-5 gear oil. Start engine and with foot on brake, shift through all gear positions, pausing 3 seconds in each. Return to Park and check fluid level with engine running at operating temperature. Add fluid as needed to bring to proper level on dipstick.

Reassembly

1. Install all underbody panels and splash shields removed during disassembly
2. Reinstall front wheels if removed and torque lug nuts to specification
3. Reconnect negative battery terminal
4. Verify no tools or parts remain in engine bay or under vehicle
5. Double-check all fluid levels including ATF, transfer case, and front differential

Verification

• Start engine and verify no unusual noises from transmission or torque converter area
• Check for fluid leaks around transmission pan, cooler lines, axle seals, and drain plug with engine running
• With engine at operating temperature and on level ground, verify transmission fluid level is within proper range on dipstick
• Test drive vehicle and verify smooth shifts through all gear ranges (P, R, N, D, and manual modes if equipped)
• Verify AWD engagement and proper operation of transfer case during test drive
• Scan for diagnostic trouble codes using OBD-II scanner and verify no transmission-related codes present
• Recheck all fluid levels after test drive and top off as necessary
• Verify shift indicator matches actual gear position on instrument cluster

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