This procedure covers the removal and replacement of the rear door lock actuator on a 2016-2024 Hyundai Tucson with the 2.5L I4 engine and AWD.

Warnings

Tools required

Parts

• Rear door lock actuator assembly × 1 — Use OEM specification for 2016-2024 Tucson
• Door panel trim clips (if damaged) × 5 — Replace any broken clips during removal

Preparation

1. Park vehicle on level surface and engage parking brake
2. Open the affected rear door completely and ensure it is stable
3. Lower rear window completely using power window switch
4. Gather all tools and new actuator assembly before beginning
5. Photograph or note the position of all electrical connectors for reference during reassembly

Procedure

1. 1

   Remove door panel trim components
   Remove the Phillips screw behind the interior door handle trim. Use a trim removal tool to carefully pry off the door handle bezel. Remove the Phillips screw located in the door pull pocket. If equipped, carefully pry out the window switch panel and disconnect the electrical connector by pressing the release tab.
2. 2

   Remove door panel mounting screws
   Locate and remove all Torx T20 screws around the perimeter of the door panel (typically 6-8 screws). Check behind any small cover caps in screw locations - pry these caps gently with a flathead screwdriver. Ensure all screws are removed before attempting to pull the panel.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
3. 3

   Detach door panel from door frame
   Starting at the bottom corners, use trim removal tools to carefully release the plastic retaining clips securing the door panel to the door frame. Work your way around the perimeter, listening for each clip to release. Once all clips are free, lift the panel upward to disengage it from the window sill channel, then pull away from door. Support the panel while disconnecting any remaining electrical connectors.
4. 4

   Remove vapor barrier access
   Carefully peel back the plastic vapor barrier in the area around the door latch mechanism. You only need to create enough access to reach the actuator - do not remove the entire barrier. The barrier is typically held by butyl tape and should remain sticky for reinstallation.
5. 5

   Disconnect actuator electrical connector
   Locate the door lock actuator electrical connector inside the door cavity. Press the locking tab and carefully disconnect the connector from the actuator. Note the connector orientation and routing of the wire harness for reinstallation.
6. 6

   Disconnect actuator linkage rods
   Identify the plastic rod clips connecting the actuator to the door latch mechanism. Use needle-nose pliers to carefully squeeze and release the rod clips from the actuator arms. Note the position and orientation of each rod connection - taking a photo is recommended. There are typically two rods: one for the lock/unlock function and one for the latch handle.
7. 7

   Remove actuator mounting fasteners
   Remove the Torx T25 screws (typically 3) securing the actuator to the door frame. Support the actuator while removing the final screw to prevent it from falling inside the door cavity. Carefully extract the actuator through the access opening in the door frame.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
8. 8

   Install new actuator
   Position the new actuator in the door frame, aligning the mounting holes with the door frame. Thread in all mounting screws by hand first to ensure proper alignment. Tighten the screws to specification using a torque wrench in a cross pattern to ensure even seating.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
9. 9

   Reconnect actuator linkage rods
   Attach the linkage rods to the new actuator arms in the same positions noted during removal. Ensure the plastic clips snap firmly into place on each rod connection. Gently tug each rod to verify secure attachment. Verify that the rod geometry allows free movement without binding.
10. 10

    Connect actuator electrical connector
    Plug the electrical connector into the new actuator, ensuring the locking tab clicks into place. Route the wire harness in the same path as originally installed to prevent interference with window mechanism or door operation.
11. 11

    Test actuator operation
    Before reinstalling the door panel, test the actuator function using the door lock switch and key fob. Verify that the lock engages and disengages smoothly without binding. Test both the inside door handle and outside door handle to ensure proper latch operation. Listen for any unusual noises during operation.
12. 12

    Reinstall vapor barrier
    Press the vapor barrier back into position, ensuring all edges are sealed against the door frame. The butyl tape should re-adhere to create a moisture seal. If the barrier has lost adhesion, apply new butyl tape around the edges to maintain the seal.
13. 13

    Reinstall door panel
    Reconnect all electrical connectors to the door panel (window switches, etc.). Position the door panel at the window sill and slide down into the channel. Align the panel with the door frame and firmly press around all perimeter areas to engage the retaining clips - you should hear each clip snap into place. Install all Torx screws and tighten to specification. Reinstall the door handle bezel, window switch panel, and any trim covers.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)

Reassembly

1. Ensure all trim panel clips are fully seated and the panel is flush with the door frame
2. Verify all electrical connectors are secure and properly locked
3. Check that no tools or parts were left inside the door cavity
4. Confirm all screws and fasteners have been reinstalled and torqued properly

Verification

• Test door lock operation from all control points: interior switch, key fob, and driver's door master switch
• Verify door latches and unlatches properly from both inside and outside handles
• Check that central locking system locks and unlocks all doors simultaneously
• Listen for smooth, quiet actuator operation without grinding or clicking noises
• Inspect door panel for proper fit with no gaps or misalignment
• Test window operation to ensure no interference from wiring or components
• Verify door closes and seals properly without rubbing on panel or components

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