This procedure covers replacement of the outer CV boot on the front axle of a 2016-2024 Hyundai Tucson with 2.5L I4 engine and AWD, requiring removal of the halfshaft from the vehicle.

Warnings

Tools required

Parts

• Outer CV boot kit with grease and clamps × 1 — Use OEM specification or quality aftermarket
• Axle nut × 1 — Use new fastener - check if staked or cotter pin type
• Cotter pin (if applicable to your specific model) × 1 — Match OEM size

Preparation

1. Park vehicle on level ground and engage parking brake
2. Loosen the front wheel lug nuts while vehicle is on the ground
3. Loosen the axle nut while the wheel is on the ground and someone applies the brakes (nut is very tight)
4. Raise the front of the vehicle and support securely on jack stands at the manufacturer designated lift points
5. Remove the front wheel on the side being serviced
6. Place drain pan underneath the work area to catch any grease drippings

Procedure

1. 1

   Remove axle nut and separate hub
   Fully remove the axle nut that was previously loosened. Remove the cotter pin or unstake the nut collar if applicable. Keep the axle nut for reference but plan to install a new one. The axle should now be free from the hub but may still be tight - you will fully separate it in later steps.
2. 2

   Disconnect lower ball joint or tie rod
   Remove the lower ball joint pinch bolt or tie rod end castle nut to allow the steering knuckle to be pivoted away from the axle. Depending on access, you may need to disconnect the lower control arm ball joint. Use a pickle fork or appropriate separator tool if the taper does not release easily. Avoid damaging the ball joint boot if reusing components.
3. 3

   Remove halfshaft from hub
   Push the axle shaft out of the hub assembly. You may need to tap the end of the shaft with a brass punch and hammer or use a puller if the splines are tight. Support the halfshaft to prevent it from hanging by the inner CV joint. Pivot the knuckle assembly outward to create clearance.
4. 4

   Remove halfshaft from transmission
   Carefully pry the inner CV joint from the transmission using a pry bar positioned against the inner joint housing (not the boot or axle shaft). Pull straight out once the circlip releases. Some transmission fluid may drain - have a drain pan ready. Support the halfshaft and remove it from the vehicle. Keep it horizontal to prevent the inner joint from coming apart.
   ⚠Do not pry against the transmission case as this can cause damage. Pry only against the inner CV joint housing.
5. 5

   Secure halfshaft and remove outer boot clamps
   Place the halfshaft in a padded vise or secure it on a clean workbench. Use side cutters to cut off the outer CV boot clamps on both the large and small diameter ends. Remove the clamps completely and slide the old boot toward the center of the shaft to expose the outer CV joint.
6. 6

   Remove outer CV joint
   Wipe away excess grease to expose the CV joint retaining mechanism. Most Tucson halfshafts use a circlip inside the joint. Tap the outer CV joint housing sharply with a brass hammer or punch to release it from the shaft, or spread the internal circlip if accessible. The joint should slide off the shaft splines. Mark the orientation if there is any directional alignment, though most are symmetrical.
7. 7

   Clean and inspect components
   Remove the old boot completely from the shaft. Clean the CV joint housing, balls, cage, and shaft thoroughly with solvent and clean rags. Inspect all surfaces for pitting, cracks, scoring, or wear. Check that the balls move smoothly in the races. If any damage is present, replace the entire halfshaft rather than continuing with boot replacement. Dry all components completely.
   ⚠Do not disassemble the CV joint ball cage and races unless absolutely necessary - they are precisely matched and difficult to reassemble correctly.
8. 8

   Install new boot and clamps
   Slide the new small boot clamp onto the axle shaft, followed by the small end of the new boot. Position the small end of the boot in the groove on the axle shaft and install the small clamp. Use the proper clamp tool to tighten securely - do not overtighten as the boot can tear. The boot should sit flat in the shaft groove with no twisting.
9. 9

   Pack CV joint with grease
   Pack the CV joint housing with the grease supplied in the boot kit (typically 80-120 grams or as specified). Distribute grease into all the ball races and around the cage. Also pack grease into the boot itself. Use all the grease supplied in the kit - CV joints require substantial lubrication.
10. 10

    Reinstall CV joint
    Align the CV joint with the shaft splines and slide it onto the shaft firmly until the circlip engages with a click or solid seating. You may need to tap it with a soft hammer. Verify the joint is fully seated and cannot be pulled off by hand.
11. 11

    Seat and clamp outer boot end
    Slide the large end of the boot over the CV joint housing and seat it in the housing groove. Burp the boot by carefully lifting the edge to allow trapped air to escape - the boot should not be ballooned or collapsed. Install the large boot clamp and tighten using the clamp tool. Verify the boot is properly seated with no twists or kinks and rotates freely around the joint.
12. 12

    Reinstall halfshaft to transmission
    Clean the inner CV joint splines and check that the circlip on the inner joint is properly seated in its groove. Align the halfshaft with the transmission output shaft and push firmly until the circlip clicks into place. Tug on the halfshaft to verify it is securely locked in - it should not pull out.
13. 13

    Reinstall halfshaft to hub and reconnect suspension
    Guide the outer end of the halfshaft into the hub assembly, aligning the splines. You may need to rotate the hub to align the splines. Push the shaft fully into the hub. Reconnect the lower ball joint or tie rod end that was disconnected earlier and install fasteners hand-tight. Pivot the knuckle back to its normal position.
14. 14

    Install new axle nut
    Install the new axle nut onto the halfshaft threads and thread it by hand to avoid cross-threading. Snug the nut with a socket but do not torque yet - final torquing will be done with the wheel installed and vehicle on the ground.
15. 15

    Reinstall wheel and torque fasteners
    Reinstall the wheel and thread the lug nuts by hand. Lower the vehicle until the tire just contacts the ground (weight still on jack stands). Torque the lug nuts to specification in a star pattern. Fully lower the vehicle to the ground. Have an assistant apply the brakes firmly and torque the axle nut to specification. Stake the nut collar or install a new cotter pin as applicable to your specific model year.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

    Axle Nut250 Nm (184 lb-ft)

Reassembly

1. Verify all suspension components disconnected during removal are properly reconnected and torqued
2. Check transmission fluid level if significant fluid was lost during inner CV joint removal
3. Inspect the work area for any tools or parts left behind

Verification

• Test drive the vehicle and verify no clicking, popping, or vibration from the repaired axle
• Turn the steering wheel full lock in both directions while driving slowly to verify the CV joint operates smoothly
• Inspect the new boot after the test drive for any signs of grease leakage or damage
• Recheck the axle nut torque after 50-100 miles of driving

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