This procedure covers the removal and replacement of both upper and lower ball joints on the front suspension of a 2016-2024 Hyundai Tucson with 2.5L I4 AWD engine.

Warnings

Tools required

Parts

• Upper ball joint (left) × 1 — Use OEM specification
• Upper ball joint (right) × 1 — Use OEM specification
• Lower ball joint (left) × 1 — Use OEM specification
• Lower ball joint (right) × 1 — Use OEM specification
• Cotter pins × 4 — 3mm diameter
• Pinch bolt × 2 — Use OEM specification
• Anti-seize compound × 1 — Copper or nickel based

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen wheel lug nuts while vehicle is on ground but do not remove
4. Raise front of vehicle with floor jack and support with jack stands under the subframe
5. Remove front wheels completely
6. Inspect suspension components for additional wear or damage before proceeding

Procedure

1. 1

   Disconnect sway bar link
   Locate the sway bar link connection at the lower control arm. Use an Allen key to hold the shaft while loosening the nut with a wrench. Remove the sway bar link from the lower control arm to provide working clearance.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
2. 2

   Remove upper ball joint cotter pin and nut
   Locate the upper ball joint at the top of the knuckle. Use diagonal cutters or a cotter pin tool to remove and discard the cotter pin. Clean threads with a wire brush. Using a breaker bar and socket, loosen and remove the upper ball joint castle nut. Do not allow the ball joint stud to spin.
   ℹ️Mark or photograph the orientation of components before disassembly for proper reassembly.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
3. 3

   Separate upper ball joint from knuckle
   Install a ball joint separator tool between the upper control arm and the steering knuckle. Tighten the separator tool to apply pressure, then strike the knuckle boss area with a hammer to shock the taper loose. Once separated, remove the separator tool and support the knuckle to prevent it from falling.
   ⚠The knuckle will drop suddenly when the ball joint separates. Support the assembly or the CV axle and brake components may be damaged.
4. 4

   Remove lower ball joint pinch bolt
   Locate the pinch bolt that clamps the lower ball joint stud to the steering knuckle. This is a through-bolt design. Remove the pinch bolt and discard it - a new bolt must be used during reassembly. Carefully pry the pinch clamp open slightly if needed to release the taper.
   ℹ️The pinch bolt is a torque-to-yield design and must not be reused.
   Torque spec

   Pinch Bolt61 Nm (45 lb-ft)
5. 5

   Remove steering knuckle
   With both ball joints disconnected, carefully remove the steering knuckle assembly from the vehicle. Support the CV axle and brake assembly with wire or a bungee cord to prevent strain on the brake hose and ABS sensor wiring. Place the knuckle on a clean work surface.
   ⚠Do not let the knuckle hang by the brake hose or CV axle. Support the assembly with wire or a suitable hook.
6. 6

   Press out old upper ball joint
   Using a ball joint press or hydraulic press with appropriate adapters, press the old upper ball joint out of the control arm. Ensure the press is aligned squarely to avoid damaging the control arm bore. Clean the bore thoroughly with a wire brush and inspect for damage or deformation.
   ⚠Ensure the press adapters are properly sized to support the control arm around the ball joint bore, not on the bore itself.
7. 7

   Press out old lower ball joint
   If the lower ball joint is pressed into the knuckle (not bolted), use the ball joint press to remove the old lower ball joint from the steering knuckle. Support the knuckle properly and press the ball joint out. Clean the bore thoroughly and inspect for damage. If the lower ball joint is bolted, remove the retaining bolts instead.
   ℹ️Some Tucson models may have bolted lower ball joints. Verify your specific configuration before pressing.
8. 8

   Install new lower ball joint
   Apply a light coat of anti-seize to the outer circumference of the new lower ball joint (not the taper). Using the ball joint press with appropriate adapters, press the new lower ball joint into the steering knuckle until it is fully seated and flush. Ensure it is oriented correctly with the stud pointing in the proper direction.
   ⚠Do not apply excessive force if the ball joint does not seat smoothly. Verify alignment and adapter sizing.
9. 9

   Install new upper ball joint
   Apply a light coat of anti-seize to the outer circumference of the new upper ball joint. Press the new upper ball joint into the control arm bore using the ball joint press until fully seated. Verify the ball joint is flush and properly oriented with the grease fitting accessible.
10. 10

    Reinstall steering knuckle assembly
    Support the knuckle and align the lower ball joint stud into the knuckle pinch clamp. Install the new pinch bolt and hand-tighten only. Raise the knuckle to align the upper ball joint stud into the upper knuckle bore. Install the upper ball joint castle nut and hand-tighten.
11. 11

    Torque ball joint fasteners
    Using a torque wrench, torque the lower ball joint pinch bolt to specification. Then torque the upper ball joint castle nut to specification. The castle nut may need to be tightened slightly beyond the torque spec to align the cotter pin hole - never loosen to align. Install a new cotter pin and bend the ends to secure.
    ⚠Always tighten the castle nut to the next slot if needed for cotter pin alignment. Never back off a properly torqued castle nut.
    Torque spec

    Ball Joint Nut88 Nm (65 lb-ft)

    Pinch Bolt61 Nm (45 lb-ft)
12. 12

    Reconnect sway bar link
    Position the sway bar link to the lower control arm. Hold the shaft with an Allen key while installing and torquing the nut to specification. Ensure the link is properly seated and not twisted.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
13. 13

    Install wheel and lower vehicle
    Install the wheel and hand-tighten the lug nuts in a star pattern. Lower the vehicle until the tires just touch the ground but the suspension is not fully loaded. Torque the wheel lug nuts to specification in a star pattern.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
14. 14

    Final torque control arm bolts with vehicle weight
    Fully lower the vehicle so the suspension is at normal ride height with vehicle weight on the wheels. If any control arm bolts were loosened during this procedure, torque them to specification now. This ensures the rubber bushings are torqued in their normal operating position.
    ⚠Control arm bushings must be torqued at ride height. Torquing while suspended will cause premature bushing failure and clunking noises.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Repeat the entire procedure for the opposite side if replacing both sides
2. Verify all cotter pins are properly installed and secured
3. Check that no tools or parts were left in the wheel well
4. Pump the brake pedal several times to ensure proper brake caliper piston position

Verification

• Perform a visual inspection of all installed components and verify proper torque on all fasteners
• Test drive the vehicle at low speed in a safe area and listen for any clunking or abnormal noises from the front suspension
• Check steering feel and verify there is no excessive play or looseness in the steering wheel
• Schedule a professional wheel alignment immediately, as ball joint replacement will alter suspension geometry
• After 50-100 miles, re-check torque on all ball joint fasteners and wheel lug nuts

More procedures for this vehicle