This procedure covers the removal and installation of the front coil springs on a 2016-2024 Hyundai Tucson 2.5L I4 AWD, requiring strut removal and use of a spring compressor.

Warnings

Tools required

Parts

• Front coil spring - left × 1 — Use OEM specification or quality aftermarket
• Front coil spring - right × 1 — Use OEM specification or quality aftermarket
• Strut mount bearing (if worn) × 2 — Inspect during disassembly
• Upper strut mount nuts (if corroded) × 6 — M10 self-locking nuts
• Ball joint castle nut and cotter pin × 2 — Replace if damaged during removal

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
3. Raise front of vehicle with floor jack and support securely on jack stands placed on frame rails behind front subframe
4. Remove both front wheels completely
5. Spray all suspension fasteners with penetrating oil and allow to soak
6. Take photos of spring positioning and orientation on both sides for reference during reassembly
7. Verify your spring compressor is rated for the vehicle weight and in good working condition

Procedure

1. 1

   Disconnect sway bar end links
   Locate the sway bar end link connecting to the strut. Hold the ball joint shaft with a 6mm Allen key to prevent spinning, then remove the upper nut using appropriate socket. Separate the end link from the strut. If ball joint spins freely, use locking pliers on the shaft boot area (not the shaft itself).
   Torque spec

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

   Separate lower ball joint from knuckle
   Remove the cotter pin from the lower ball joint castle nut. Remove the ball joint nut completely. Use a ball joint separator or pickle fork to separate the ball joint from the steering knuckle. Avoid damaging the ball joint boot if reusing the control arm. Support the lower control arm with a jack to prevent it from dropping.
   ⚠The lower control arm will drop when the ball joint separates. Have a floor jack positioned under the control arm to prevent sudden movement and possible injury.
   Torque spec

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

   Disconnect strut from steering knuckle
   Locate the two bolts connecting the strut to the steering knuckle bracket. These are large 17mm or 18mm bolts with nuts on the backside. Remove both bolts completely. You may need to use a pry bar to separate the knuckle from the strut bracket once bolts are removed. Support the strut with one hand to prevent it from falling.
   ⚠The strut assembly is heavy (approximately 15-20 lbs). Support it during removal to prevent it from falling and causing injury.
   Torque spec

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

   Remove strut tower mounting nuts
   Open the hood and locate the strut tower under the plastic cover (if equipped). Remove any plastic covers to access the three upper strut mount nuts. Have an assistant support the strut assembly from below, or use a transmission jack. Remove all three nuts while supporting the strut. Carefully lower the complete strut assembly out of the wheel well.
   ⚠️Do not allow the strut assembly to fall. Ensure it is properly supported before removing the final mounting nut.
   Torque spec

   Strut Tower Nuts50 Nm (37 lb-ft)
5. 5

   Install spring compressor on strut
   Place the strut assembly in a vise or secure work area with the strut shaft pointing up. Install the spring compressor according to manufacturer instructions, ensuring the compressor hooks engage at least 3 full coils on opposite sides of the spring. The compressor must be centered and symmetrical. Begin compressing the spring slowly and evenly, alternating between both sides of the compressor. Compress until the spring tension is completely released from the upper mount (you should be able to wiggle the mount freely).
   ⚠️This is the most dangerous step. Verify the spring compressor is properly engaged before applying any compression. Compress slowly and check alignment frequently. An improperly installed compressor can cause the spring to shoot out violently.
   ⚠Never place any body part in line with the spring ends during compression. Stand to the side of the assembly.
6. 6

   Remove strut shaft nut and disassemble
   With the spring fully compressed and tension released, use a strut rod socket or crowfoot wrench to remove the center shaft nut while holding the strut shaft with an Allen key or strut shaft holder. Remove the upper mount assembly, bearing plate, upper spring seat/insulator, dust boot, and bump stop in order. Note the orientation and position of each component. Remove the compressed spring carefully. Inspect the strut mount bearing for roughness or binding - replace if worn.
   ⚠️Keep the spring compressed and controlled at all times. Do not release the spring compressor until the spring is separated from the strut.
7. 7

   Transfer spring compressor to new spring
   Before releasing the old spring, note the exact position of the compressor hooks and amount of compression. Place the new spring on a flat surface and install the spring compressor in the same positions as the old spring. Compress the new spring to approximately the same compression as the old spring. Verify the spring end positioning matches your reference photos - the spring end must align with the pocket in the lower spring seat.
   ⚠New springs may have a different free height than old springs. Ensure adequate compression for installation but do not over-compress.
8. 8

   Reassemble strut with new spring
   Slide the compressed new spring onto the strut body, ensuring the lower spring end seats properly in the lower spring seat pocket. Install the bump stop, dust boot, upper spring insulator/seat (oriented correctly per reference photos), bearing plate, and upper mount in reverse order of removal. Thread the strut shaft nut onto the shaft by hand. Hold the strut shaft and torque the center nut to specification using strut rod socket. Slowly and evenly release the spring compressor, verifying the spring seats properly in both upper and lower seats. Remove the compressor completely.
   ⚠Watch the spring alignment carefully as you release the compressor. If the spring end is not properly seated, it will shift violently when tension is released. Re-compress and correct alignment if needed.
9. 9

   Install strut assembly into vehicle
   Lift the complete strut assembly into the wheel well from below. Align the upper mount studs with the holes in the strut tower. Install the three upper strut tower nuts and tighten to specification. Guide the lower strut bracket into position on the steering knuckle.
   Torque spec

   Strut Tower Nuts50 Nm (37 lb-ft)
10. 10

    Connect strut to steering knuckle
    Align the strut bracket with the steering knuckle mounting holes. You may need to use a pry bar to align the holes. Install both strut-to-knuckle bolts from the front with nuts on the rear. Torque both bolts to specification.
    Torque spec

    Strut Bolts115 Nm (85 lb-ft)
11. 11

    Reconnect lower ball joint
    Use a floor jack to raise the lower control arm and align the ball joint stud with the hole in the steering knuckle. Install the ball joint castle nut and torque to specification. Install a new cotter pin through the castle nut slots and ball joint stud. Bend the cotter pin ends to secure. If the castle nut slots don't align with the cotter pin hole, tighten the nut additional (never loosen to align).
    ⚠The ball joint castle nut must be secured with a cotter pin. Never operate the vehicle without the cotter pin installed.
    Torque spec

    Ball Joint Nut88 Nm (65 lb-ft)
12. 12

    Reconnect sway bar end link
    Align the sway bar end link with the mounting point on the strut. Install the nut while holding the ball joint shaft with a 6mm Allen key. Torque the nut to specification.
    Torque spec

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

    Repeat for opposite side
    Perform steps 1 through 12 for the opposite side strut assembly. Ensure both springs are installed with identical orientation and positioning.
    ℹ️Springs must be installed as a matched pair with identical orientation to maintain proper vehicle handling and alignment.
14. 14

    Install wheels and lower vehicle
    Install both front wheels and hand-thread all lug nuts. Lower the vehicle until the wheels just touch the ground (weight not fully on suspension). Torque the wheel lug nuts to specification in a star pattern. Fully lower the vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Verify all fasteners are properly torqued, especially strut tower nuts, strut bolts, and ball joint nuts
2. Verify cotter pins are installed in both ball joint castle nuts
3. Check that both springs are oriented identically with spring ends in proper pockets
4. Bounce each corner of the vehicle several times to settle the suspension

Verification

• Test drive the vehicle at low speed in a safe area, listening for any clunks, rattles, or unusual noises from the front suspension
• Verify steering feels normal with no binding or unusual resistance
• Check that vehicle sits level side-to-side with no visible lean
• Schedule a professional front-end alignment within 24 hours - new springs will change alignment angles
• Re-torque all suspension fasteners after 50-100 miles of driving
• Visually inspect under the vehicle for any loose components or fasteners after test drive

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