This procedure covers the inspection and replacement of exhaust system rubber hangers on the 2016-2024 Hyundai Tucson 2.5L I4 AWD to eliminate rattles, sagging exhaust components, or excessive movement.

Warnings

Tools required

Parts

• Exhaust rubber hanger(s) × 1 — Use OEM specification - typically 28675-series part numbers
• Exhaust flange gasket (if disturbing exhaust connections) × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks behind front wheels
3. Ensure exhaust system is completely cool to the touch
4. Raise rear of vehicle using floor jack at designated lift points on rear subframe
5. Support vehicle securely on jack stands rated for vehicle weight (approximately 3,700 lbs)
6. Inspect exhaust system from underneath to identify which hangers are damaged or deteriorated
7. Spray penetrating oil on any corroded exhaust fasteners if flange separation will be required for hanger access

Procedure

1. 1

   Locate and inspect exhaust hangers
   Identify all exhaust hanger locations from front to rear of vehicle. The 2.5L AWD Tucson typically has 4-6 rubber hangers supporting the exhaust system: one near the catalytic converter/downpipe junction, one or two at the mid-pipe section, and two at the rear muffler assembly. Visually inspect each hanger for cracking, tearing, excessive wear, or complete separation from mounting brackets.
2. 2

   Support exhaust system weight
   Position a floor jack with a wooden block or rubber pad under the exhaust component nearest to the hanger being replaced. Raise the jack just enough to take weight off the hanger without lifting the exhaust - this prevents the pipe from dropping when the hanger is removed and makes installation of the new hanger easier.
3. 3

   Remove damaged hanger from exhaust pipe bracket
   Using a flathead screwdriver or small pry bar, carefully work the rubber hanger eye off the exhaust pipe mounting hook. The hanger is under tension, so apply steady controlled pressure while pulling the hanger away from the hook. If the rubber is severely deteriorated, it may tear during removal - this is normal for failed hangers. For stubborn hangers, spray with soapy water as lubricant.
4. 4

   Remove hanger from chassis mounting bracket
   Once freed from the exhaust pipe side, remove the other end of the rubber hanger from the chassis-mounted bracket hook. Some hangers may be bolted to the chassis bracket - if so, remove the mounting bolt using appropriate socket. Note the orientation and position of the hanger for proper installation of the replacement.
5. 5

   Clean mounting points and inspect brackets
   Use a wire brush to clean both the exhaust pipe hook and chassis bracket mounting point, removing any rust, debris, or old rubber residue. Inspect both metal brackets for cracks, excessive corrosion, or damage. If brackets are bent or damaged, they must be replaced or straightened before installing new hangers. Check that chassis bracket bolts are secure.
6. 6

   Install new exhaust hanger
   Begin installation by attaching one end of the new rubber hanger to the chassis bracket first - this is typically easier than starting with the exhaust side. If the hanger has a bolt-on design, install the mounting bolt but do not fully tighten yet. For hook-style mounts, stretch the rubber eye over the chassis hook using a prying motion with the screwdriver. Apply soapy water to ease installation if needed.
   Torque spec

   Hanger Bolts20 Nm (15 lb-ft)
7. 7

   Attach hanger to exhaust pipe bracket
   With the chassis side secured, use the pry bar or screwdriver to stretch the opposite end of the rubber hanger over the exhaust pipe mounting hook. This will require significant force as the hanger must be under tension to properly support the exhaust. Ensure the hanger is fully seated on both hooks and centered properly. If equipped with hanger bolts, torque to specification.
8. 8

   Verify exhaust alignment and clearance
   Lower the jack supporting the exhaust weight and allow the system to settle into its natural position supported by all hangers. Check clearance between exhaust pipes and all surrounding components including rear differential, driveshaft, fuel tank, chassis rails, and underbody panels. Minimum clearance should be 15-20mm at all points. Adjust hanger positions if necessary to center the exhaust system.
9. 9

   Test exhaust for movement and security
   Manually push and pull on exhaust components to verify hangers are properly seated and provide adequate support. The exhaust should have minimal side-to-side or up-and-down movement (approximately 10-15mm is normal). Excessive movement indicates improper hanger installation or additional worn hangers. Listen for any rattling or contact points when moving the exhaust.

Reassembly

1. If any exhaust flange connections were separated for hanger access, install new gaskets and torque flange bolts to specification with anti-seize compound applied to threads
2. If heat shields were removed for access, reinstall and torque mounting bolts to specification
3. Verify all exhaust hangers are properly seated and supporting the system before lowering vehicle
4. Remove jack stands and carefully lower vehicle to ground

Verification

• Start engine and allow to idle - listen for exhaust leaks or unusual rattling sounds from the hanger area
• With engine running, have an assistant apply throttle while you observe exhaust movement from underneath - excessive lateral or vertical movement indicates hanger failure or improper installation
• Verify no contact between exhaust components and chassis, driveshaft, or fuel system components during engine operation
• Test drive vehicle over varied road conditions (bumps, turns, acceleration) and listen for exhaust rattles or knocking sounds that would indicate loose or improperly installed hangers
• After test drive, perform final visual inspection of hanger installation and recheck clearances while exhaust is at operating temperature

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