This procedure covers removal and installation of the rear driveshaft on AWD 2016-2024 Hyundai Tucson models equipped with the 2.5L I4 engine.

Warnings

Tools required

Parts

• Rear driveshaft assembly × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil (rear differential, if needed) — 2 qt

Preparation

1. Park vehicle on level surface, engage parking brake, and place transmission in Park
2. Chock the front wheels securely
3. Raise the rear of the vehicle and support on jack stands at the rear subframe or axle stand points
4. Remove rear wheels to provide better access if needed (optional but recommended)
5. Allow exhaust system to cool completely

Procedure

1. 1

   Mark driveshaft orientation
   Using a paint marker or scribe, make alignment marks on the driveshaft flange and the rear differential input flange. Also mark the driveshaft to transfer case flange at the front. These marks ensure the driveshaft is reinstalled in the exact same orientation to prevent balance issues and vibration.
2. 2

   Support the driveshaft
   Position a transmission jack or floor jack with a wooden block under the center of the driveshaft to support its weight. Alternatively, have an assistant ready to support the driveshaft during removal. Secure with mechanic's wire if working alone to prevent the shaft from dropping.
3. 3

   Remove rear differential mounting bolts
   Locate the four bolts connecting the rear driveshaft flange to the rear differential input flange. Using a 14mm socket, remove all four bolts. Note that these are the CV bolts connection. Keep the bolts organized as they will be reused.
   ⚠Support the rear of the driveshaft before removing the final bolt to prevent it from falling.
4. 4

   Separate rear connection
   Carefully pull the driveshaft flange away from the differential input flange. There may be some resistance from the pilot engagement. Use a small pry bar if needed, working carefully to avoid damaging the flange faces. Lower the rear of the driveshaft slightly.
5. 5

   Remove center bearing support bolts
   Locate the center support bearing mounted to the vehicle underbody. Remove the two or three mounting bolts securing the center bearing bracket using a 12mm or 14mm socket. Keep these bolts separate as they may differ from the flange bolts.
6. 6

   Remove front transfer case connection
   At the front of the driveshaft, remove the four bolts connecting the driveshaft to the transfer case output flange using a 14mm socket. Align your marks to ensure proper reference during reinstallation. Support the driveshaft weight during removal of the final bolt.
   ⚠The entire driveshaft weight will now be free. Ensure adequate support before removing the final bolt.
7. 7

   Remove driveshaft assembly
   Carefully lower and remove the complete driveshaft assembly from under the vehicle. Maneuver it around any exhaust components, fuel lines, or brake lines. Inspect the driveshaft for signs of damage, wear at the U-joints or CV joints, torn boots, or imbalance weights that may have come loose.
8. 8

   Inspect mounting points
   With the driveshaft removed, inspect the transfer case output flange and rear differential input flange for wear, damage, or debris. Clean both flange surfaces with brake cleaner. Check the center support bearing mount on the chassis for cracks or damage. Inspect all bolt holes for thread damage.
9. 9

   Install new or serviced driveshaft
   Lift the driveshaft into position, aligning the center support bearing bracket with its mounting location. Install the front flange to the transfer case output flange first, aligning your reference marks made during disassembly. Start all four bolts by hand before tightening any.
10. 10

    Torque front connection
    Using a torque wrench, tighten the four front flange bolts connecting the driveshaft to the transfer case output flange. Torque in a criss-cross pattern to the specified value to ensure even seating and prevent flange distortion.
11. 11

    Install center bearing support
    Align the center support bearing bracket with the chassis mounting holes. Install the mounting bolts and torque to specification. Ensure the bearing is properly seated and not under any binding or preload stress.
12. 12

    Connect rear differential flange
    Raise the rear of the driveshaft and align the flange with the rear differential input flange, matching your alignment marks. The pilot portion should engage smoothly. Start all four bolts by hand, ensuring proper thread engagement.
13. 13

    Torque rear connection
    Using a torque wrench, tighten the four rear flange bolts in a criss-cross pattern to the specified torque value. This ensures even pressure distribution and proper sealing of the flange connection.
14. 14

    Final inspection
    Remove the jack or support from under the driveshaft. Visually verify all bolts are installed and torqued. Check for adequate clearance between the driveshaft and all surrounding components throughout its full rotation. Rotate the driveshaft by hand if possible to check for binding or interference.

Reassembly

1. Reinstall rear wheels if removed and torque lug nuts to specification in a star pattern
2. Lower the vehicle to the ground
3. Test drive the vehicle at various speeds (25-65 mph) to check for vibration or unusual noises
4. If vibration is present, verify alignment marks were matched and all fasteners are properly torqued

Verification

• Start the engine and shift through all gears to verify no abnormal noises from the driveline
• Perform a test drive and accelerate through 0-50 mph, checking for smooth power delivery with no vibration, clunking, or binding
• Listen for any clicking, grinding, or humming noises during acceleration, deceleration, and steady-state driving
• Check underneath the vehicle after test drive for any signs of fluid leakage at the differential or transfer case flanges
• Verify no check engine lights or AWD system warning lights are illuminated on the dashboard

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