This procedure covers the removal and replacement of the rear CV axle assembly on 2016-2024 Hyundai Tucson AWD models with the 2.5L I4 engine.

Warnings

Tools required

Parts

• Rear CV axle assembly × 1 — Use OEM specification for side being replaced
• Axle nut (if staking required) × 1 — Use OEM specification
• Ball joint castle nut (if damaged) × 1 — Use OEM specification
• Cotter pin for ball joint × 1 — Use OEM specification
• 75W-90 GL-5 Gear Oil × 1 — Rear differential refill

Fluids

• 75W-90 GL-5 Gear Oil — 2 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Loosen rear wheel lug nuts while vehicle is on the ground (do not remove)
3. Loosen but do not remove the rear axle nut while vehicle is on the ground - this nut is very tight and requires a breaker bar
4. Raise and support the rear of the vehicle on jack stands positioned on the frame or designated lift points
5. Remove the rear wheel on the side being serviced
6. Place drain pan under the rear differential to catch gear oil
7. If axle nut has been staked, use center punch or chisel to unstake the nut before attempting removal

Procedure

1. 1

   Remove axle nut
   With the vehicle supported and wheel removed, completely remove the rear axle nut that was previously loosened. If the nut was staked into the axle groove, ensure it has been properly unstaked. Keep the nut if it will be reused (not staked type), otherwise discard and use a new nut.
   Torque spec

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

   Disconnect lower control arm ball joint
   Locate the lower control arm ball joint connection at the rear knuckle. Remove the cotter pin and castle nut from the ball joint stud. Use a ball joint separator tool or pickle fork to separate the ball joint from the knuckle. Avoid damaging the ball joint boot if reusing the control arm.
   Torque spec

   Ball Joint Nut102 Nm (75 lb-ft)
3. 3

   Remove inner CV axle bolts
   At the differential end of the axle, locate the CV joint flange bolts (typically 6 bolts). Support the axle with one hand or have an assistant hold it. Remove all CV joint flange bolts that connect the inner CV joint to the differential output flange. Keep these bolts for reinstallation.
   ⚠Gear oil will begin draining from the differential once the axle is separated. Ensure drain pan is properly positioned.
   Torque spec

   CV Bolts61 Nm (45 lb-ft)
4. 4

   Remove CV axle from hub
   Pull the outer end of the axle shaft out of the rear wheel hub assembly. If the axle is stuck in the hub splines, tap the end with a brass or plastic hammer. Simultaneously pull the inner CV joint away from the differential flange. Maneuver the entire axle assembly out from under the vehicle.
5. 5

   Inspect hub and differential
   Clean the hub splines with a wire brush and inspect for damage or excessive wear. Check the differential output flange for damage, wear, or fluid leaks at the seal. Inspect the lower control arm ball joint and boot for damage. Clean the differential flange mating surface.
6. 6

   Install new CV axle into hub
   Position the new CV axle assembly. Insert the outer splined end into the rear hub, ensuring it is fully seated into the hub bearing splines. Align the inner CV joint with the differential output flange. Thread the new axle nut onto the stub axle a few turns by hand to hold the axle in position.
7. 7

   Connect inner CV joint to differential
   Align the inner CV joint flange with the differential output flange bolt holes. Install all CV joint flange bolts finger-tight first to ensure proper alignment. Torque all bolts to specification in a star pattern to ensure even seating of the joint.
   Torque spec

   CV Bolts61 Nm (45 lb-ft)
8. 8

   Reconnect lower control arm ball joint
   Position the lower control arm ball joint stud into the knuckle. Install the castle nut and torque to specification. Install a new cotter pin through the castle nut and ball joint stud, bending the ends to secure it properly.
   Torque spec

   Ball Joint Nut102 Nm (75 lb-ft)
9. 9

   Torque axle nut
   With the parking brake engaged and the vehicle still on jack stands, torque the axle nut to specification. If using a staked-type nut, after torquing, use a center punch to stake the nut collar into the axle groove at the designated staking point. If reusing a non-staked nut, ensure it is in good condition.
   ℹ️Some model years require a new staked nut for each installation. Verify your specific requirement.
   Torque spec

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

    Refill rear differential
    Locate the rear differential fill plug (typically on the front or side of the differential housing). Remove the fill plug and add 75W-90 GL-5 gear oil until it begins to seep out of the fill hole. The rear differential capacity is approximately 2.0 quarts. Reinstall and tighten the fill plug.
11. 11

    Reinstall wheel and lower vehicle
    Install the rear wheel and thread lug nuts by hand. Lower the vehicle until the tire just touches the ground but the suspension is not fully loaded. 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. Ensure all fasteners have been torqued to specification, particularly the axle nut and CV bolts
2. Verify the differential has been refilled to the proper level
3. Check that the axle nut has been properly staked if using a staked-type nut
4. Verify the ball joint cotter pin is properly installed and secured

Verification

• Test drive the vehicle in a safe area, making slow speed turns in both directions to verify no clicking, popping, or binding from the CV axle
• Check for any gear oil leaks around the differential flange and fill plug after the test drive
• Verify no unusual vibrations or noises from the rear axle during acceleration and deceleration
• Recheck the axle nut torque after 50-100 miles of driving to ensure it has not loosened

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