This procedure covers removal and installation of the front CV axle on a 2016-2024 Hyundai Tucson with 2.5L I4 AWD engine, including disconnecting the lower ball joint and separating the axle from the front differential.

Warnings

Tools required

Parts

• CV axle assembly (left or right) × 1 — Use OEM specification for specific side
• Axle nut × 1 — Use new nut each time
• Ball joint pinch bolt × 1 — Reusable unless damaged
• Front differential drain plug gasket × 1 — OEM recommended

Fluids

• 75W-90 GL-5 Gear Oil — 1.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is on the ground (do not remove)
4. With vehicle still on ground and brakes applied, use breaker bar to crack loose the 32mm axle nut (do not remove completely)
5. Raise front of vehicle and support securely on jack stands at frame rails
6. Remove front wheel on the side being serviced
7. Place drain pan under front differential

Procedure

1. 1

   Remove axle nut
   Fully remove the 32mm axle nut that was previously loosened. The nut will either have a staked collar or a cotter pin depending on previous installation. Discard the old nut as a new one must be used during reassembly.
   Torque spec

   Axle Nut244 Nm (180 lb-ft)
2. 2

   Disconnect lower ball joint
   Locate the lower ball joint pinch bolt connecting the lower control arm to the steering knuckle. Remove the pinch bolt completely. Use a ball joint separator or pickle fork to separate the ball joint from the knuckle. You may need to tap the separator with a hammer to break the taper loose.
   Torque spec

   Ball Joint Pinch Bolt55 Nm (41 lb-ft)
3. 3

   Support the knuckle assembly
   Pull the steering knuckle outward and down slightly to create clearance. The CV axle splines should now be free from the wheel hub. If the axle is stuck in the hub, tap the end gently with a dead blow hammer or use a brass drift. Do not allow the knuckle to hang by the brake hose.
   ⚠Support the knuckle and brake assembly with a bungee cord or wire to prevent strain on the brake hose and ABS sensor wiring.
4. 4

   Remove inner CV joint from differential
   Insert a pry bar between the inner CV joint housing and the differential case. Pry firmly to pop the CV axle out of the differential. You will feel a distinct pop as the circlip releases. Pull the entire axle assembly out from the vehicle. Expect approximately 0.5-1.0 quarts of gear oil to drain from the differential opening.
   ⚠Do not pry against the CV boot or you may damage it. Pry only against the metal housing.
5. 5

   Inspect components
   Inspect the CV axle boots for tears, cracks, or grease leakage. Check the differential seal for damage or leakage. Inspect the wheel hub splines for wear or damage. Clean the differential opening and hub splines with a wire brush. If the differential seal is damaged, it should be replaced before installing the new axle.
   ℹ️If replacing only one axle on an AWD vehicle, ensure the replacement axle is the exact same length and specification as the original to prevent driveline issues.
6. 6

   Install new CV axle into differential
   Ensure the circlip on the inner CV joint is properly seated in its groove. Align the inner CV joint with the differential opening and push firmly until you hear and feel the circlip snap into place. Give the axle a firm tug outward to verify it is locked in position.
   ℹ️The circlip must be fully seated or the axle may pull out during operation. Verify engagement by pulling on the axle.
7. 7

   Install outer CV joint into hub
   Guide the outer CV joint splines into the wheel hub. Push the knuckle assembly inward and align the splines. You may need to rotate the axle slightly to engage the splines. Push firmly until the axle is fully seated in the hub.
   ⚠Do not force the axle. If it does not slide in easily, verify spline alignment and clean any debris from the hub.
8. 8

   Reconnect lower ball joint
   Align the lower ball joint stud with the steering knuckle. Push the knuckle down onto the ball joint stud until fully seated. Install the pinch bolt in the same orientation as removed. Tighten the pinch bolt to specification.
   Torque spec

   Ball Joint Pinch Bolt55 Nm (41 lb-ft)
9. 9

   Install and torque new axle nut
   Install the NEW 32mm axle nut onto the CV axle threads. Use a torque wrench to tighten to the specified torque. After torquing, stake the nut collar into the groove on the axle shaft using a punch and hammer to prevent loosening. Make sure the stake creates a visible indent that locks the nut.
   ⚠A new axle nut must be used every time. The staking or cotter pin method used depends on the specific nut design.
   Torque spec

   Axle Nut244 Nm (180 lb-ft)
10. 10

    Refill front differential
    Using a fluid pump or squeeze bottle, refill the front differential with 1.5 quarts of 75W-90 GL-5 gear oil through the fill plug opening. Fill until oil begins to seep from the fill hole, then install the fill plug with a new gasket if applicable.
    ℹ️Use only GL-5 specification gear oil. GL-4 is not suitable for this application.
11. 11

    Reinstall wheel and lower vehicle
    Install the wheel and hand-tighten the lug nuts in a star pattern. Lower the vehicle until the tire just touches the ground. Torque the 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. Double-check that the axle nut has been properly staked or pinned
2. Verify the ball joint pinch bolt is fully torqued
3. Check the front differential oil level through the fill plug after the vehicle has sat level for a few minutes
4. Wipe up any spilled gear oil from the differential area and undercarriage

Verification

• Start the engine and turn the steering wheel lock-to-lock while stationary to verify no binding or clicking noises
• Test drive the vehicle at low speed and verify no vibration, clicking, or popping from the CV axle during acceleration and turning
• After test drive, recheck the front differential for leaks around the axle seal
• Verify the axle nut is still properly torqued and staked
• Check for any gear oil leaks from the differential fill or drain plugs

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