This procedure covers the replacement of rear control arm bushings on a 2016-2024 Hyundai Tucson 2.5L AWD by removing the control arm assembly, pressing out old bushings, installing new bushings, and reinstalling the arm with proper torque specifications.

Warnings

Tools required

Parts

• Rear control arm bushing kit (inner and outer bushings) × 1 — Use OEM specification
• Cotter pin (if equipped with ball joint) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen rear wheel lug nuts while vehicle is on ground
3. Raise rear of vehicle and support securely on jack stands at frame rails
4. Remove rear wheel on side being serviced
5. Spray penetrating oil on all control arm mounting bolts and ball joint connections, allow to soak 10-15 minutes
6. Place floor jack under rear knuckle to support suspension at ride height

Procedure

1. 1

   Disconnect sway bar link
   Locate the rear sway bar link connection to the control arm or knuckle. Use an Allen key to hold the shaft of the sway bar link from rotating while removing the nut with a wrench. Disconnect the sway bar link from the control arm or suspension component to provide clearance.
   Torque spec

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

   Remove ball joint connection
   If your control arm connects via ball joint to the knuckle, remove the cotter pin (if equipped) and discard. Remove the ball joint nut. Use a ball joint separator tool or pickle fork to separate the ball joint taper from the knuckle. Avoid damaging the ball joint boot if reusing the control arm for bushing service.
   ⚠Support the suspension with a jack before separating the ball joint to prevent sudden drop.
   Torque spec

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

   Mark control arm position
   Before removing the control arm mounting bolts, use a paint marker or scribe to mark the position of the control arm relative to the subframe/mounting brackets. This helps with approximate reinstallation positioning. Take photos for reference.
4. 4

   Remove control arm mounting bolts
   Remove the front and rear control arm mounting bolts that secure the arm to the subframe or chassis. These are typically large diameter bolts passing through the control arm bushings. Use a breaker bar if necessary. Note the orientation of any washers or spacers for reinstallation. Remove the control arm from the vehicle.
   ℹ️Control arm may be heavy and awkward to handle once bolts are removed.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
5. 5

   Inspect control arm and bushings
   Clean the control arm thoroughly with a wire brush. Inspect the control arm for cracks, bends, or damage. Examine the old bushings to identify which ones need replacement. Typically both inner and outer bushings should be replaced as a set. Note the orientation and depth of the existing bushings before removal.
6. 6

   Press out old bushings
   Using a hydraulic press and appropriate bushing removal adapters, carefully press out the old bushings from the control arm. Apply pressure evenly and slowly. The bushing outer shell is press-fit into the control arm bore. Ensure you are pressing on the bushing outer shell, not just the rubber portion. Clean the control arm bore thoroughly after bushing removal.
   ⚠Ensure proper adapter alignment to prevent damage to control arm bore. Misalignment can crack or deform the control arm.
7. 7

   Prepare new bushings
   Compare new bushings to old bushings to verify correct parts. Apply a light coat of soapy water or bushing installation lubricant to the outer shell of the new bushings and the control arm bore. Do not use oil or grease as this can cause bushing migration. Verify proper orientation of bushings noting any offset or directional markings.
8. 8

   Press in new bushings
   Using the hydraulic press and appropriate installation adapters, press the new bushings into the control arm bores. Apply even pressure and ensure the bushing is entering straight. Press until the bushing is seated to the correct depth, typically flush with the control arm bore or to the depth of the original bushing. Verify bushing orientation matches OEM specifications.
   ⚠Do not over-press bushings beyond specified depth as this can damage the bushing or control arm.
9. 9

   Install control arm to vehicle
   Position the control arm back into the mounting location on the subframe. Insert the front and rear mounting bolts through the bushings and into the chassis mounts. Hand-thread the bolts but do NOT torque them at this time. The bolts must be torqued with the vehicle weight on the wheels to prevent bushing preload and premature wear.
10. 10

    Reconnect ball joint
    Align the ball joint stud with the knuckle taper. Install the ball joint nut and tighten to specification. If equipped with a cotter pin, install a new cotter pin through the castle nut and ball joint stud, bending the ends to secure. Ensure the ball joint boot is not damaged or twisted.
    ⚠Always use a new cotter pin. Never reuse old cotter pins.
    Torque spec

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

    Reconnect sway bar link
    Reconnect the sway bar link to the control arm or suspension mounting point. Hold the shaft with an Allen key to prevent rotation 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 rear wheel and hand-tighten the lug nuts in a star pattern. Lower the vehicle to the ground so the full weight is on the wheels. This loads the suspension to the normal ride height position.
13. 13

    Torque control arm bolts with vehicle on ground
    With the vehicle weight fully on the wheels, torque the control arm front and rear mounting bolts to specification. This is critical to prevent bushing bind and premature failure. The bushings must be torqued at ride height to allow proper articulation.
    ⚠This step is critical. Torquing control arm bolts with suspension hanging will cause bushing failure within a few thousand miles.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
14. 14

    Final torque wheel lug nuts
    Torque the wheel lug nuts to specification in a star pattern using a torque wrench.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Repeat all steps for the opposite side if replacing both rear control arm bushings
2. Ensure all fasteners are torqued to specification
3. Verify no tools or parts were left in the wheel well area

Verification

• Test drive the vehicle at low speed and verify no clunking or unusual noises from the rear suspension
• Check for proper handling and stability during turns and over bumps
• Have a professional alignment performed to verify rear suspension geometry is within specification
• Re-check all torque specifications after 50-100 miles of driving
• Inspect for any fluid leaks or loose connections in the rear suspension area

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