Replace the front lower control arm bushings on a 2016-2024 Hyundai Tucson 2.5L AWD by removing the control arm, pressing out old bushings, installing new ones, and reinstalling with proper torque specifications.

Warnings

Tools required

Parts

• Front lower control arm bushing kit (2 bushings per arm) × 2 — Use OEM specification
• Cotter pin for ball joint × 1 — Use OEM specification

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front 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 front wheel on side being serviced
6. Apply penetrating oil to control arm bolts, ball joint nut, and any corroded fasteners; allow to soak 15-20 minutes

Procedure

1. 1

   Remove ball joint cotter pin and nut
   Locate the ball joint nut where the lower control arm connects to the steering knuckle. Use cotter pin puller or needle-nose pliers to remove and discard the cotter pin. Using a 17mm socket, remove the ball joint nut completely. Keep nut for torque reference if reusing.
2. 2

   Separate ball joint from knuckle
   Install ball joint separator tool between the control arm and knuckle. Tighten the tool to apply pressure to the ball joint taper. Strike the knuckle boss area sharply with a hammer while maintaining pressure to break the taper seal. Alternatively, use a pickle fork by driving it between the joint, but note this may damage the ball joint boot. Once separated, remove the separator tool.
   ⚠Do not strike the ball joint stud threads directly as this will damage them and prevent proper nut installation.
3. 3

   Disconnect sway bar link if necessary
   If the sway bar link interferes with control arm removal, use an Allen key to hold the shaft while removing the nut with an appropriate wrench. Separate the link from the control arm. This step may not be necessary on all model years depending on clearance.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
4. 4

   Remove control arm mounting bolts
   Locate the two control arm mounting bolts that attach the arm to the subframe. These are through-bolts with nuts on the opposite side. Using an 18mm wrench and socket, remove both bolts completely. Note the orientation and any washers or spacers for reinstallation. Support the control arm as you remove the final bolt.
   ℹ️Take photos of bolt orientation and washer placement before removal for reference during installation.
5. 5

   Remove control arm from vehicle
   Maneuver the control arm out of the wheel well. You may need to angle it and rotate to clear the subframe and steering components. Inspect the ball joint and arm for damage while removed.
6. 6

   Mark bushing orientation
   Before pressing out bushings, mark the orientation of each bushing in the control arm using a paint marker or scribe. Note any offset positioning or directional features. Front and rear bushings may have different designs.
   ⚠Bushings are directional and must be installed in the correct orientation. Incorrect installation will cause binding and premature failure.
7. 7

   Press out old bushings
   Using a hydraulic press with appropriately sized adapters, press out the old bushings from the control arm. Apply pressure evenly and ensure the control arm is properly supported. The inner sleeve may need to be pressed out separately from the outer bushing housing depending on design. Clean the bushing bores thoroughly with a wire brush and inspect for damage or deformation.
   ⚠Ensure press adapters are sized correctly to avoid damaging the control arm bushing bore. Adapter should contact only the bushing, not the arm.
8. 8

   Install new bushings
   Position new bushings in the control arm bores matching the orientation marks made earlier. Apply light coating of supplied lubricant (if provided) or soapy water to ease installation. Using the hydraulic press with proper adapters, press the new bushings into place until fully seated. The bushing should be flush or match the original depth. Press slowly and ensure the bushing enters straight without cocking.
   ⚠Do not use petroleum-based lubricants on rubber bushings as this will degrade the rubber. Use only water-based lubricant or supplied grease.
9. 9

   Install control arm to subframe
   Position the control arm back into the vehicle, aligning the bushing holes with the subframe mounting points. Insert both control arm bolts through the bushings and subframe. Install washers and nuts finger-tight only. Do NOT torque at this time - bolts must be torqued with vehicle weight on wheels.
10. 10

    Connect ball joint to knuckle
    Align the ball joint stud with the hole in the steering knuckle. You may need to use a pry bar or jack to maneuver the knuckle into position. Insert the ball joint stud fully into the knuckle and install the nut. Torque the ball joint nut to specification. Install a new cotter pin through the castle nut and stud, bending the ends to secure.
    Torque spec

    Ball Joint Nut88 Nm (65 lb-ft)
11. 11

    Reconnect sway bar link if removed
    If the sway bar link was disconnected, reconnect it to the control arm. Hold the shaft with an Allen key and torque the nut to specification.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
12. 12

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

    Wheel Lug Nuts136 Nm (100 lb-ft)
13. 13

    Final torque control arm bolts with weight on wheels
    Lower the vehicle completely so full weight is on the wheels. Rock the vehicle side to side to settle the suspension. Using a torque wrench, torque both control arm mounting bolts to specification. This step is critical - torquing with suspension hanging will preload bushings incorrectly and cause premature failure.
    ⚠️Control arm bolts MUST be torqued with vehicle weight on wheels at normal ride height. Failure to do this will destroy the new bushings within a few thousand miles.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Repeat all steps for opposite side if replacing both control arm bushings
2. Verify all fasteners are torqued to specification
3. Ensure new cotter pin is properly installed and bent on ball joint nut

Verification

• Test drive vehicle at low speed and verify no abnormal noises from front suspension
• Check for proper steering response and return to center
• Verify no clunking or knocking over bumps
• Schedule front end alignment within 50 miles - control arm removal will affect alignment settings
• Re-check control arm bolt torque after 100 miles of driving

More procedures for this vehicle