This procedure covers the replacement of the front upper control arm bushings on a 2016-2024 Hyundai Tucson with the 2.5L I4 AWD engine by removing the control arm assembly and pressing in new bushings.

Warnings

Tools required

Parts

• Front upper control arm bushing kit (left and/or right) × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is on ground
4. Raise front of vehicle and support securely on jack stands at manufacturer-specified jacking points
5. Remove front wheels completely
6. Spray all fasteners with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Disconnect upper ball joint from knuckle
   Remove the cotter pin from the upper ball joint castle nut. Using a socket and breaker bar, loosen and remove the ball joint nut. Use a ball joint separator tool to press the ball joint taper out of the steering knuckle. If using a pickle fork, position it between the control arm and knuckle and strike firmly until the taper releases. Do not damage the ball joint boot.
2. 2

   Support the steering knuckle
   Once the ball joint is separated, the knuckle assembly will drop. Use a bungee cord or wire to support the knuckle and prevent stress on the brake hose and ABS sensor wiring. Ensure the CV axle is not hanging at an extreme angle.
3. 3

   Remove control arm mounting bolts
   Locate the two control arm mounting bolts that attach the control arm to the frame/subframe. These bolts pass through the bushings. Using a socket and breaker bar, remove both bolts completely. Note the orientation of any washers or alignment marks. The control arm can now be removed from the vehicle.
4. 4

   Inspect and clean control arm
   With the control arm on a workbench, inspect the ball joint for play or torn boots. Clean the bushing mounting areas with a wire brush, removing all rust and debris. Mark the orientation of the old bushings before removal if they have directional installation.
5. 5

   Press out old bushings
   Using a hydraulic press with appropriate sized adapters, press the old bushings out of the control arm. Position the control arm so the bushing is supported around its outer edge, and press from the center. Apply even pressure and ensure the control arm does not shift during pressing. Repeat for second bushing if applicable.
6. 6

   Prepare and press in new bushings
   Clean the bushing bores in the control arm thoroughly. Apply a light coat of soapy water or approved bushing lubricant to the new bushing outer diameter (do not use oil or grease). Align the bushing correctly according to any orientation marks or voids. Using the hydraulic press and correct adapters, press the new bushing straight into the control arm bore until fully seated and flush. Ensure the bushing is not cocked or damaged during installation.
7. 7

   Reinstall control arm to frame
   Position the control arm back into its mounting location on the frame/subframe. Insert both control arm mounting bolts through the bushings and thread them into place by hand. Do NOT torque these bolts yet - they must be torqued with vehicle weight on the suspension. Snug the bolts finger-tight plus one turn to hold the arm in place.
8. 8

   Reconnect ball joint to knuckle
   Remove the support from the steering knuckle and align the upper ball joint stud with the hole in the knuckle. Insert the ball joint stud fully into the knuckle taper. Install the castle nut and tighten to specification. Align the castle nut slots with the ball joint stud hole and install a new cotter pin. Bend the cotter pin ends to secure.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
9. 9

   Reinstall wheels and lower vehicle
   Reinstall the front wheel and thread lug nuts by hand. Lower the vehicle until the tires just touch the ground but the suspension is not yet loaded. Torque the wheel lug nuts in a star pattern to specification. Fully lower the vehicle so all weight is on the wheels.
   Torque spec

   Wheel Lug Nuts136 Nm (100 lb-ft)
10. 10

    Torque control arm bolts with vehicle loaded
    With the vehicle fully on the ground and weight on the suspension, torque both control arm mounting bolts to specification. This is critical - torquing these bolts while the suspension is hanging will cause the bushings to bind and fail prematurely. Torque in the proper sequence if specified by the manufacturer.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification in the proper sequence
2. Verify the new cotter pin is properly installed and secured
3. Check that no tools or parts were left in the wheel well or suspension area

Verification

• Bounce the front of the vehicle several times to settle the suspension, then re-check all torque specifications
• Perform a visual inspection of the control arm installation to ensure proper alignment and no interference
• Test drive the vehicle at low speed and verify no unusual noises, vibrations, or handling issues
• Schedule a professional wheel alignment within 50 miles as suspension geometry has been disturbed

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