This procedure covers removal and replacement of the lower ball joint on a 2016-2024 Hyundai Tucson 2.5L AWD, including separation from the knuckle and control arm installation.

Warnings

Tools required

Parts

• Lower ball joint assembly × 1 — Use OEM specification
• Cotter pin × 1 — 2.5mm x 25mm
• Pinch bolt (if applicable) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen wheel lug nuts while vehicle is on ground
3. Raise front of vehicle and support securely on jack stands at manufacturer's lift points
4. Remove wheel and tire assembly
5. Spray all fasteners with penetrating lubricant and allow to soak for 10-15 minutes

Procedure

1. 1

   Remove cotter pin and ball joint nut
   Straighten and remove the cotter pin from the ball joint castle nut. Use a 17mm socket to remove the ball joint nut. Do not fully remove the nut yet; leave it threaded on a few turns to protect threads during separation.
2. 2

   Separate ball joint from steering knuckle
   Using a ball joint separator or pickle fork, separate the ball joint stud from the steering knuckle. Position the separator between the control arm and knuckle, then strike with a hammer or apply pressure until the taper releases. Remove the castle nut completely once the joint is separated. Support the knuckle to prevent strain on the CV axle and brake hose.
   ⚠The knuckle will drop when the ball joint separates. Support it with a floor jack or wire to prevent damaging the CV axle boot or brake line.
3. 3

   Access control arm mounting bolts
   If necessary for access, disconnect the sway bar link from the lower control arm using the appropriate socket while holding the shaft with an Allen key. Position a floor jack under the control arm to support it during removal.
   ℹ️Depending on ball joint configuration and access, you may be able to leave the control arm partially installed. Assess whether full control arm removal is necessary.
4. 4

   Remove control arm bolts (if full removal required)
   Using an 18mm socket and breaker bar, remove the front and rear control arm mounting bolts from the subframe. Note the orientation and position of any washers or alignment marks. Carefully lower the control arm from the vehicle while guiding it past the CV axle and brake components.
   ℹ️Take photos or mark the control arm position before removal to aid in reinstallation and alignment.
5. 5

   Remove old ball joint from control arm
   If the ball joint is bolted to the control arm, remove the mounting bolts and separate the ball joint. If the ball joint is pressed into the control arm, a hydraulic press or ball joint press tool will be required. Support the control arm on the press bed and use the appropriate adapters to press the old ball joint out from below.
   ⚠Ensure press adapters are properly sized and centered to avoid damaging the control arm during ball joint removal.
6. 6

   Clean mounting surfaces
   Use a wire brush to thoroughly clean the ball joint mounting bore in the control arm and the tapered seat in the steering knuckle. Remove all rust, dirt, and debris. Inspect the control arm for cracks, damage, or excessive wear in the bushings.
7. 7

   Install new ball joint
   If pressed-in type, position the new ball joint in the control arm bore with the correct orientation (grease fitting facing appropriate direction). Use a hydraulic press with proper adapters to press the ball joint into place until fully seated. If bolt-on type, position the new ball joint and install mounting bolts to manufacturer specifications.
   ⚠Press only on the outer ball joint housing, never on the stud. Ensure the ball joint is square and fully seated in the bore.
8. 8

   Reinstall control arm to subframe
   Position the control arm back into the vehicle, guiding it into place. Insert the front and rear mounting bolts but do not fully tighten yet. Thread the bolts enough to hold the control arm in position. If removed, reconnect the sway bar link to the control arm.
9. 9

   Connect ball joint to steering knuckle
   Raise the control arm or lower the knuckle to align the ball joint stud with the hole in the steering knuckle. Insert the stud through the knuckle and thread on the new castle nut. Tighten the castle nut to the specified torque of 88-102 Nm (65-75 lb-ft). Align the castle nut slots with the stud hole and install a new cotter pin. Bend the cotter pin ends to secure.
   ℹ️If castle nut slots do not align with the cotter pin hole at specified torque, tighten further up to the maximum specification. Never loosen to align.
   Torque spec

   Ball Joint Nut102 Nm (75 lb-ft)
10. 10

    Reconnect sway bar link (if disconnected)
    If the sway bar link was removed, reconnect it to the control arm. Hold the shaft with an Allen key while torquing the nut to specification.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
11. 11

    Install wheel and lower vehicle to load suspension
    Install the wheel and tire assembly. Thread lug nuts by hand, then snug them in a star pattern with a socket. Lower the vehicle until the tires just contact the ground but the suspension is not fully loaded. This allows the suspension to settle to ride height before final torquing.
12. 12

    Torque control arm bolts with vehicle weight on wheels
    With the vehicle at normal ride height (weight on wheels but not fully lowered off jack stands), torque the front and rear control arm mounting bolts to 165 Nm (122 lb-ft). This is critical for proper bushing alignment and lifespan.
    ⚠Control arm bolts MUST be torqued at ride height. Torquing with suspension hanging can cause premature bushing failure and noise.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
13. 13

    Lower vehicle and torque wheel lug nuts
    Fully lower the vehicle to the ground and remove jack stands. Torque the wheel lug nuts to 136 Nm (100 lb-ft) in a star pattern.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification in the correct sequence
2. Verify cotter pin is properly installed and bent to prevent castle nut loosening
3. Double-check that control arm bolts were torqued at ride height, not with suspension hanging

Verification

• Test drive the vehicle at low speed and verify no clunking or abnormal noises from the front suspension
• Check for proper steering response and verify the steering wheel returns to center
• Perform a visual inspection under the vehicle to confirm all fasteners are tight and the cotter pin is secure
• Schedule a professional wheel alignment as suspension geometry will have changed during ball joint replacement

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