This procedure covers removal and replacement of the upper ball joint on the 2016-2024 Hyundai Tucson 2.5L AWD, which may require pressing out the old ball joint and installing a new one into the control arm.

Warnings

Tools required

Parts

• Upper ball joint × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification
• Pinch bolt (if applicable) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen wheel lug nuts while vehicle is on ground (do not remove)
4. Raise front of vehicle and support securely on jack stands at manufacturer-specified jacking points
5. Remove wheel and tire assembly completely
6. Spray all ball joint fasteners with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Remove cotter pin and ball joint castle nut
   Locate the upper ball joint at the top of the steering knuckle. Straighten and remove the cotter pin from the ball joint castle nut using pliers or a cotter pin removal tool. Discard the cotter pin. Using the appropriate socket, remove the ball joint castle nut but do not fully separate the joint yet.
2. 2

   Separate ball joint from steering knuckle
   Using a ball joint separator tool or pickle fork, carefully separate the upper ball joint taper from the steering knuckle. Position the tool between the control arm and knuckle, then apply force to break the taper fit. If using a pickle fork, note that it may damage the ball joint boot (acceptable if replacing). The knuckle may drop slightly when separated; support with a wire or bungee cord if needed.
   ⚠Ball joint may release suddenly when taper breaks free. Keep fingers clear of pinch points.
3. 3

   Support steering knuckle assembly
   Once the ball joint is separated, the steering knuckle and hub assembly will be loose. Support the knuckle assembly with a wire, bungee cord, or have an assistant hold it to prevent strain on the brake hose and ABS sensor wiring. Do not let the knuckle hang freely by the brake components.
4. 4

   Access upper control arm bolts (if required)
   Depending on ball joint design, you may need to remove the entire upper control arm. If the ball joint is pressed into the control arm, remove the control arm mounting bolts from the frame. These bolts are located near the strut tower. Support the control arm as you remove the bolts. If ball joint is serviceable in-vehicle, skip to step 6.
5. 5

   Remove upper control arm from vehicle
   Once all mounting bolts are removed, carefully maneuver the upper control arm out of the wheel well. Note the orientation and position of any washers, bushings, or alignment shims for reinstallation. Clean the mounting area with a wire brush.
6. 6

   Press out old ball joint
   Secure the control arm in a vise or on a hydraulic press bed. Using the appropriate sized receivers and adapters from your ball joint press kit, position the tool to press the old ball joint out of the control arm bore. Apply steady pressure until the ball joint is fully removed. Inspect the control arm bore for damage, scoring, or deformation.
   ⚠Ensure press adapters are properly aligned to avoid damaging the control arm. Use receiver cups that fully support the control arm around the ball joint bore.
7. 7

   Clean ball joint bore and prepare for installation
   Thoroughly clean the ball joint bore in the control arm using a wire brush to remove any rust, dirt, or debris. Inspect for cracks or damage. Apply a thin coat of anti-seize compound to the outer diameter of the new ball joint (not the taper) to ease installation and future removal.
8. 8

   Press in new ball joint
   Position the new ball joint in the control arm bore with proper orientation (taper facing down toward knuckle). Using the ball joint press with appropriate adapters, apply steady pressure to press the new ball joint into the control arm until it is fully seated. Ensure the ball joint is pressed in squarely and seats completely against the control arm shoulder.
   ⚠Do not press on the ball stud itself; apply pressure only to the outer housing. Ensure the ball joint is not cocked or misaligned during installation.
9. 9

   Reinstall upper control arm to vehicle
   If the control arm was removed, position it back into the mounting location with any original shims, washers, or bushings in their correct positions. Start all mounting bolts by hand before tightening. Do not fully torque control arm bolts at this time if the specification requires vehicle weight on wheels.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
10. 10

    Connect ball joint to steering knuckle
    Remove any support holding the steering knuckle. Align the ball joint stud with the hole in the top of the steering knuckle. The taper must seat fully into the knuckle bore. Install the castle nut and tighten to the specified torque. If using the lower torque spec (88 Nm / 65 lb-ft), proceed to install cotter pin. If using the higher spec (102 Nm / 75 lb-ft), this likely requires alignment for cotter pin hole.
    ℹ️Castle nut may need to be tightened beyond minimum torque to align cotter pin holes. Never loosen the nut to align holes; only tighten further up to maximum specification.
    Torque spec

    Ball Joint Nut102 Nm (75 lb-ft)
11. 11

    Install new cotter pin
    Insert a new cotter pin through the castle nut and ball joint stud hole. Bend the legs of the cotter pin in opposite directions to secure it. Ensure the cotter pin is fully seated and properly secured to prevent the castle nut from loosening.
12. 12

    Reinstall wheel and lower vehicle
    Install the wheel and tire assembly onto the hub. Thread all lug nuts by hand to prevent cross-threading. Tighten lug nuts in a star pattern until snug but do not torque yet. Lower the vehicle until the tire just contacts the ground but suspension is not fully loaded.
13. 13

    Torque wheel lug nuts and control arm bolts
    With the vehicle weight partially on the wheels, torque the wheel lug nuts to specification in a star pattern. Then lower the vehicle completely so full weight is on the suspension. If control arm bolts were installed and require torquing with vehicle weight on wheels, torque them now to specification.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification before returning vehicle to service
2. Verify cotter pin is properly installed and secured
3. Check that no tools or parts were left in the wheel well area

Verification

• Test drive vehicle at low speed and verify no unusual noises from the front suspension
• Check for proper steering feel and response with no binding or looseness
• Visually inspect ball joint area for proper installation and secure fasteners
• Schedule a professional wheel alignment as ball joint replacement affects suspension geometry

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