This procedure covers removal and installation of the front driveshaft (propeller shaft) on AWD 2016-2024 Hyundai Tucson vehicles with the 2.5L I4 engine, connecting the transfer case to the front differential.

Warnings

Tools required

Parts

• Front differential drain plug washer × 1 — Use OEM specification
• Differential cover gasket (if equipped) × 1 — Use OEM specification or RTV sealant
• Thread locker (medium strength) × 1 — Loctite 243 or equivalent

Fluids

• 75W-90 GL-5 Gear Oil — 1.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow drivetrain to cool if vehicle was recently operated
3. Raise front of vehicle and support securely on jack stands at manufacturer-specified lift points
4. Remove front skid plate or undertray if equipped to access driveshaft
5. Place drain pan under front differential

Procedure

1. 1

   Drain front differential fluid
   Locate the front differential drain plug on the bottom of the differential housing. Using appropriate socket, remove drain plug and allow gear oil to drain completely into drain pan. Remove fill plug on side of differential to allow air in and promote complete drainage. Inspect drain plug washer for damage and replace if necessary.
2. 2

   Mark driveshaft alignment
   Before removing any fasteners, use a marker or paint pen to mark the relationship between the driveshaft and both the transfer case output flange and front differential input flange. This ensures proper reinstallation and maintains factory balance. Mark both ends clearly with alignment marks that span the joint.
3. 3

   Remove front differential mounting bolts
   Access the front driveshaft at the differential end. Remove the bolts connecting the driveshaft CV joint or U-joint to the front differential input flange. Support the driveshaft with one hand while removing the final fasteners to prevent it from falling. If equipped with CV bolts, remove all bolts completely.
   ⚠Support driveshaft weight to prevent damage to transfer case output seal when disconnecting.
4. 4

   Remove transfer case end connection
   Move to the rear of the front driveshaft where it connects to the transfer case output. If equipped with U-joint straps, remove the strap bolts while supporting the driveshaft. If equipped with CV-style connection, remove mounting bolts. Keep all hardware organized.
5. 5

   Remove center bearing support (if equipped)
   Some configurations include a center support bearing mounted to the chassis or subframe. If your vehicle has this feature, remove the mounting bolts securing the center bearing bracket to the vehicle. Support the driveshaft during removal.
6. 6

   Remove front driveshaft assembly
   Carefully lower and remove the front driveshaft from the vehicle. Slide it rearward first to clear the differential splines if applicable, then maneuver it out from under the vehicle. Be careful not to damage the transfer case output seal or differential input seal during removal. Inspect driveshaft for damaged boots, worn U-joints, or center bearing wear.
7. 7

   Inspect and clean mating surfaces
   With driveshaft removed, inspect both the transfer case output flange and front differential input flange for wear, damage, or metal debris. Use wire brush to clean all mating surfaces and bolt holes. Check output seals for leakage. Remove any old thread locker from bolt holes.
8. 8

   Install front driveshaft
   Position the front driveshaft into the vehicle and align it with your previously marked alignment points. Start by connecting the transfer case end first, ensuring proper spline engagement if applicable. Apply medium-strength thread locker to fastener threads. Install bolts or U-joint strap hardware finger-tight initially.
   ⚠Ensure alignment marks match exactly to prevent driveline vibration.
9. 9

   Connect and torque transfer case end
   With driveshaft aligned to marks, install all fasteners at the transfer case connection. If equipped with U-joint straps, tighten strap bolts evenly in a cross pattern. Torque to specification using a calibrated torque wrench.
10. 10

    Install center bearing support (if equipped)
    If vehicle has center support bearing, position the bearing bracket to the chassis mounting location. Ensure rubber isolator is properly seated. Install mounting bolts and torque to specification.
11. 11

    Connect and torque differential end
    Align the differential end of the driveshaft with the input flange using your alignment marks. Apply medium-strength thread locker to bolt threads. Install all CV bolts or flange bolts. Tighten in a cross pattern to ensure even seating, then torque to specification.
12. 12

    Refill front differential
    Install differential drain plug with new washer and torque to specification. Using gear oil pump or transfer bottle, add 1.5 quarts of 75W-90 GL-5 gear oil through the fill hole until fluid reaches the bottom of the fill hole opening. Oil should just begin to seep out when full. Install fill plug and torque to specification.
    ℹ️Vehicle must be level when filling differential to ensure proper fluid level.
13. 13

    Final inspection and cleanup
    Wipe down all components and check for any loose fasteners. Verify all connections are secure and torqued properly. Clean any spilled gear oil. Reinstall front skid plate or undertray if equipped and torque fasteners appropriately.

Reassembly

1. Double-check that all alignment marks are properly matched at both ends of driveshaft
2. Verify all torque specifications have been met with calibrated torque wrench
3. Confirm front differential is filled to proper level with correct specification gear oil
4. Ensure no tools or parts are left under vehicle before lowering

Verification

• Lower vehicle and start engine, shift through all gears to verify proper operation
• Take vehicle for test drive and accelerate moderately while monitoring for vibrations or unusual noises
• Listen for clunking sounds during acceleration and deceleration which may indicate loose fasteners
• After test drive, re-check all driveshaft fasteners for proper torque
• Inspect front differential for leaks around drain and fill plugs after 24 hours of operation
• Monitor for any driveline vibration during highway speeds; vibration may indicate misalignment

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