This procedure covers removal and replacement of the front coil springs on a 2016-2024 Hyundai Tucson 2.5L AWD, requiring strut disassembly with a spring compressor.

Warnings

Tools required

Parts

• Front coil spring (left or right as needed) × 1 — Use OEM specification or quality aftermarket equivalent
• Strut mount bearing (recommended) × 1 — Use OEM specification
• Strut upper mount (recommended) × 1 — Use OEM specification
• Ball joint nut (if damaged) × 1 — Use OEM specification
• Sway bar link (if worn) × 1 — Use OEM specification

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Chock rear wheels securely
3. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
4. Raise front of vehicle and support on jack stands at manufacturer-specified jacking points on frame rails
5. Remove front wheel on side being serviced
6. Spray all suspension fasteners with penetrating oil and allow to soak for 15 minutes
7. Support lower control arm with floor jack positioned under the ball joint area (spring pressure will be on control arm)
8. Take photos of strut orientation and spring positioning for reassembly reference

Procedure

1. 1

   Disconnect sway bar link
   Locate the sway bar link connecting the sway bar to the strut. Use an Allen key to hold the shaft while loosening the upper nut with a 14mm wrench. Remove the nut and separate the link from the strut. If the ball joint spins freely and cannot be held, use locking pliers on the boot area carefully or replace the link.
2. 2

   Disconnect ball joint from knuckle
   Remove the cotter pin (if equipped) from the lower ball joint castle nut. Using a 19mm socket, loosen but do not fully remove the ball joint nut - leave it threaded on 2-3 turns to protect threads. Use a ball joint separator tool to break the taper between the ball joint and steering knuckle. Once separated, remove the nut completely and swing the knuckle outward. Support the knuckle with wire or bungee cord to prevent strain on the brake hose and CV axle.
   ⚠Keep the jack supporting the lower control arm in place. The spring is compressed and will forcefully extend if support is removed.
3. 3

   Mark and remove strut-to-knuckle bolts
   Mark the position of the strut relative to the steering knuckle using a paint pen or scribe for camber reference during reassembly. Remove the two 17mm strut-to-knuckle bolts. You may need to use a pry bar to spread the knuckle slightly to slide the strut out. Carefully maneuver the strut assembly out from the knuckle.
4. 4

   Remove strut tower nuts
   Open the hood and locate the three strut tower mounting nuts under the plastic cover in the engine compartment. Remove the cover if present. Using a 14mm socket, remove the three nuts securing the strut to the tower. Carefully lower the strut assembly completely out of the vehicle. The assembly is heavy and awkward - control its descent.
5. 5

   Install spring compressor
   Place the strut assembly in a secure vise or strut holding fixture. Install the coil spring compressor tools according to manufacturer instructions, ensuring the compressor hooks are properly seated in the coil spring grooves. Install compressors on opposite sides of the spring (180 degrees apart) for balanced compression. Ensure the compressor tools are not contacting the strut body or mount.
   ⚠️Verify spring compressor hooks are fully engaged in spring coils before applying compression. Improperly installed compressors can slip off under load causing catastrophic spring release.
6. 6

   Compress spring
   Slowly and evenly compress the spring by alternating between the two compressor tools. Compress in small increments (2-3 turns per side) to maintain even compression. Continue until the spring is completely unloaded from the upper strut mount and has visible gap between spring and mount seats. The strut shaft should move freely up and down.
   ⚠️Compress the spring evenly and slowly. Never stand directly over the spring during compression. Wear face protection.
7. 7

   Remove strut shaft nut
   Using a strut rod holding tool, impact-rated Allen socket, or box wrench on the shaft flats (typically 6mm or 8mm Allen), hold the strut shaft from rotating. Use a 17mm or 19mm socket to remove the strut shaft nut at the top of the assembly. Remove the nut, washer, and upper mount components. Keep all parts in order for reassembly.
8. 8

   Disassemble strut components
   Remove the upper strut mount, mount bearing, upper spring seat, bump stop, and dust boot from the strut shaft. Note the orientation of each component, especially the upper spring seat tab alignment. Remove the compressed spring from the strut. Keep the spring compressors installed and set the old spring aside safely.
9. 9

   Install new spring on strut
   If the new spring is not pre-compressed, install spring compressors as in Step 5 and compress until it will fit on the strut. Slide the compressed new spring onto the strut shaft. Install the dust boot and bump stop onto the strut shaft. Install the upper spring seat with the tab aligned to the positioning mark on the strut (typically aligned with the lower bracket). Install the bearing and upper mount in their correct orientation.
   ⚠Verify the bottom of the spring is properly seated in the lower spring seat on the strut body before proceeding. Misalignment will cause noise and premature wear.
10. 10

    Install strut shaft nut
    Thread the strut shaft nut onto the shaft. Hold the shaft with the holding tool and torque the nut to 50 Nm (37 lb-ft) using the torque wrench. Verify all components are properly seated and aligned. The spring should be centered on both upper and lower seats.
    Torque spec

    Strut Tower Nuts50 Nm (37 lb-ft)
11. 11

    Release spring compressor
    Slowly and evenly release the spring compressor tools by alternating between them in small increments. As the spring extends, verify it remains properly seated in both the upper and lower spring seats. Once the spring is fully extended and supporting the upper mount, completely remove the compressor tools.
    ⚠️Release compression slowly and evenly. Monitor spring alignment continuously during release. If spring becomes misaligned, stop immediately and recompress to correct.
12. 12

    Install strut assembly in vehicle
    Lift the strut assembly into the strut tower, aligning the three studs with the holes in the tower. Install the three strut tower nuts hand-tight. Guide the lower end of the strut into position at the steering knuckle. You may need to spread the knuckle slightly with a pry bar.
13. 13

    Install strut-to-knuckle bolts
    Align the strut to the marks made during disassembly for camber reference. Insert the two strut-to-knuckle bolts and install nuts. Torque both bolts to 115 Nm (85 lb-ft).
    Torque spec

    Strut Bolts115 Nm (85 lb-ft)
14. 14

    Torque strut tower nuts
    From under the hood, torque the three strut tower mounting nuts to 50 Nm (37 lb-ft) in a star pattern. Reinstall the plastic cover if equipped.
    Torque spec

    Strut Tower Nuts50 Nm (37 lb-ft)
15. 15

    Reconnect ball joint and sway bar link
    Remove the support wire from the knuckle. Pull the knuckle back into position and insert the ball joint stud into the knuckle. Install the ball joint nut and torque to 88 Nm (65 lb-ft). Install a new cotter pin if equipped. Connect the sway bar link to the strut. Hold the shaft with an Allen key and torque the nut to 55 Nm (41 lb-ft).
    Torque spec

    Ball Joint Nut88 Nm (65 lb-ft)

    Sway Bar Link Nuts55 Nm (41 lb-ft)
16. 16

    Install wheel and lower vehicle
    Remove the jack from under the control arm. Install the wheel and thread lug nuts by hand. Lower the vehicle until the tire just contacts the ground. Torque lug nuts to 136 Nm (100 lb-ft) in a star pattern. Fully lower the vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Repeat the entire procedure for the opposite side if replacing both front springs (highly recommended for even ride height)
2. Bounce each corner of the vehicle several times to settle the suspension
3. Verify all fasteners are torqued to specification
4. Check that no tools or parts were left in the engine compartment or wheel well

Verification

• Test drive the vehicle at low speed in a safe area and verify no unusual noises from the front suspension
• Verify the vehicle sits level and at proper ride height compared to specifications
• Check for any fluid leaks around strut or brake components
• REQUIRED: Schedule a professional four-wheel alignment immediately - suspension geometry has been disturbed and alignment is essential for safe handling and tire wear
• After 50-100 miles, re-torque all suspension fasteners and verify lug nut torque
• Monitor for any unusual tire wear patterns over the next 500 miles

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