This procedure covers removal and installation of the rear coil springs on a 2016-2024 Hyundai Tucson 2.5L AWD, requiring suspension disassembly and spring compressor use.

Warnings

Tools required

Parts

• Rear coil spring × 1 — Use OEM specification or equivalent for 2.5L AWD model
• Upper spring isolator/pad × 1 — Inspect and replace if damaged
• Lower spring isolator/pad × 1 — Inspect and replace if damaged

Preparation

1. Park vehicle on level, solid ground and engage parking brake. Chock front wheels securely.
2. Loosen rear wheel lug nuts while vehicle is on ground (do not remove).
3. Raise rear of vehicle with floor jack and support with jack stands under manufacturer-specified jacking points on chassis/frame rails.
4. Remove rear wheel completely on side being serviced.
5. Spray penetrating oil on strut bolts, control arm bolts, and sway bar link nuts; allow 10-15 minutes to penetrate.
6. Inspect coil spring compressor tools for damage or wear; ensure threads operate smoothly and hooks are not bent or cracked.

Procedure

1. 1

   Support rear knuckle assembly
   Place floor jack under the rear lower control arm or knuckle assembly to support the weight of the suspension. Raise just enough to take light load off the suspension, but do not lift the vehicle. This support must remain throughout disassembly to control component movement.
   ⚠The jack must remain in position throughout spring removal to prevent sudden dropping of suspension components.
2. 2

   Disconnect sway bar link
   Locate the rear sway bar end link where it connects to the lower control arm or knuckle. Insert an Allen key into the shaft end to prevent rotation, then remove the lower nut using a wrench. Separate the link from the mounting point. If link is seized, allow additional penetrating oil and use heat carefully if necessary.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
3. 3

   Remove lower strut mounting bolts
   Locate the two bolts connecting the strut assembly to the rear knuckle (these pass through the lower portion of the strut). Support the strut with one hand or wire, then remove both bolts completely. The strut will pivot upward once bolts are removed.
   ⚠Strut assembly will pivot freely once bolts are removed. Use wire or support to prevent damage to brake lines or ABS sensors.
   Torque spec

   Strut Bolts115 Nm (85 lb-ft)
4. 4

   Lower suspension to access spring
   Slowly and carefully lower the floor jack supporting the knuckle assembly. This will allow the lower control arm to drop and expose the coil spring. Lower only enough to create working space around the spring (typically 4-6 inches of drop). Monitor brake lines and ABS wiring to ensure no excessive tension.
   ⚠Lower suspension slowly while watching all brake lines, ABS wiring, and parking brake cables for tension. Stop if any component becomes tight.
5. 5

   Install spring compressor
   Install coil spring compressor tools on opposite sides of the spring (180 degrees apart), positioned as close to center of spring length as possible. Ensure compressor hooks fully engage coil windings with at least 2-3 coils between hook sets. Verify both compressors are securely attached and aligned before proceeding.
   ⚠️Spring compressor hooks MUST fully engage the coil windings. Partial engagement can cause the compressor to slip off under load, releasing spring energy violently.
6. 6

   Compress coil spring
   Alternately tighten each spring compressor in small increments (2-3 turns at a time), switching between compressors to maintain even compression. Continue until spring is compressed enough to be loose in its mounting position (spring should be free from upper and lower seats with visible gap). This typically requires 2-4 inches of compression.
   ⚠️Compress evenly and gradually. Never fully compress one side before the other, as this can cause spring to bind or shift suddenly.
   ⚠Maintain firm grip on compressor tools. If resistance suddenly changes or tools feel loose, stop immediately and reinspect hook engagement.
7. 7

   Remove coil spring assembly
   Once spring is fully compressed and loose, carefully remove it from the vehicle along with the spring compressors still attached. Note the orientation of the spring end positions and any directional markings. Remove upper and lower spring isolators/pads from their seats and inspect for damage, cracking, or compression set. Replace isolators if worn.
8. 8

   Transfer compressors to new spring
   If installing a new spring, carefully release compression on old spring in controlled manner (alternating sides, small increments). Install compressors on new spring in same positions as old spring, ensuring proper hook engagement. Compress new spring to same compressed length as old spring was when removed from vehicle.
   ⚠️When releasing compression on old spring, maintain control and release gradually. Spring will expand forcefully if released quickly.
9. 9

   Install spring isolators and position spring
   Install lower spring isolator/pad into the seat on the lower control arm, ensuring it is fully seated in any locating features. Position the compressed spring assembly into place with the lower end seated on the isolator. Install upper isolator/pad on top of spring, aligning with upper spring seat on chassis/strut mount. Verify spring end orientations match original installation.
   ⚠Spring ends must be properly oriented in their seats. Incorrect positioning can cause spring to shift under load.
10. 10

    Raise suspension and align strut
    Use the floor jack to carefully raise the lower control arm/knuckle assembly. As you raise, guide the strut assembly into alignment with the knuckle mounting holes. Continue raising until bolt holes align and spring is seated with light preload between upper and lower seats.
11. 11

    Install strut mounting bolts
    Insert both strut-to-knuckle bolts and thread nuts onto the bolts. Do not fully torque at this time; tighten only enough to hold components in position (snug-tight). Ensure strut sits flush against knuckle mounting surface before proceeding.
    Torque spec

    Strut Bolts115 Nm (85 lb-ft)
12. 12

    Release spring compressors
    With suspension raised and strut bolts installed, carefully and gradually release tension on spring compressors by alternating between them in small increments. As spring expands, verify it remains properly seated in upper and lower seats. Once compressors are completely unloaded and loose, remove them from the spring.
    ⚠Monitor spring position as compressors are released. If spring begins to shift or move out of seats, stop and reposition before continuing.
13. 13

    Reconnect sway bar link
    Position sway bar link into the lower mounting point on control arm or knuckle. Install nut and use Allen key to hold shaft while tightening nut to specification.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
14. 14

    Torque suspension fasteners
    With vehicle still on jack stands and suspension at normal ride height position (jack supporting control arm at ride height), torque the strut-to-knuckle bolts to specification. Verify all other suspension connections are secure.
    ⚠Suspension fasteners must be torqued with suspension at ride height to prevent binding and premature bushing wear.
    Torque spec

    Strut Bolts115 Nm (85 lb-ft)
15. 15

    Reinstall wheel and lower vehicle
    Install wheel and thread lug nuts hand-tight. Lower vehicle to ground and remove jack stands. With vehicle weight on wheels, torque lug nuts to specification in star pattern. Remove wheel chocks.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Repeat procedure for opposite side if replacing both rear springs (recommended for even ride height and handling).
2. After both sides are complete, bounce each corner of the vehicle several times to settle suspension components into their normal positions.
3. Verify no tools or parts were left in wheel wells or under vehicle.

Verification

• Test drive vehicle at low speed in a safe area, listening for any unusual noises from rear suspension (clunks, rattles, or squeaks may indicate improperly seated spring or loose fasteners).
• Verify vehicle sits level side-to-side and front-to-back when parked on level ground.
• Check that steering and handling feel normal with no pulling to either side.
• After 50-100 miles of driving, re-torque wheel lug nuts to specification and visually inspect strut bolts and sway bar link for any looseness.
• Consider professional wheel alignment check, as suspension work can affect toe and camber settings.

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