This procedure covers removal and replacement of the flexplate on a 2016-2024 Hyundai Tucson with 2.5L I4 AWD engine, requiring transmission removal for access.

Warnings

Tools required

Parts

• Flexplate × 1 — Use OEM specification
• Flexplate bolts × 8 — Use OEM specification
• Transmission pan gasket × 1 — Use OEM specification
• Transmission filter (if equipped) × 1 — Use OEM specification
• Transmission drain plug gasket × 1 — Use OEM specification

Fluids

• Hyundai SP-IV-M ATF — 10 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable and secure away from terminal
3. Raise vehicle on lift or support securely on jack stands at all four corners
4. Remove engine under covers and splash shields
5. Place drain pan under transmission and drain ATF from transmission drain plug
6. Remove front wheels for access to subframe mounting points
7. Install engine support bar across engine bay to support engine weight during transmission removal

Procedure

1. 1

   Remove exhaust components
   Disconnect exhaust system from catalytic converter forward. Remove exhaust hangers and lower exhaust system to provide clearance for transmission removal. Support exhaust with wire or stand to prevent damage to oxygen sensors.
2. 2

   Disconnect driveshafts and transfer case
   Mark front and rear driveshaft positions relative to flanges with paint or punch marks. Remove front driveshaft mounting bolts and rear driveshaft mounting bolts. Support driveshafts and remove completely. Disconnect transfer case electrical connections and vent hoses. Drain transfer case fluid into appropriate container.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
3. 3

   Disconnect transmission connections
   Disconnect transmission wiring harness connectors including shift solenoids, speed sensors, and temperature sensors. Remove transmission cooler lines by releasing quick-connect fittings or removing threaded connections. Plug all open lines to prevent contamination. Disconnect shift cable from transmission lever and bracket.
   ⚠Residual ATF will drain from cooler lines. Position drain pan to catch fluid.
4. 4

   Support and remove transmission crossmember
   Position transmission jack under transmission pan with wooden block to distribute load. Secure transmission to jack with safety chain or strap. Remove transmission crossmember mounting bolts and lower crossmember away from vehicle. Verify engine support bar is properly supporting engine weight.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
5. 5

   Remove starter motor
   Disconnect starter motor electrical connections including main power cable and trigger wire. Remove starter mounting bolts and extract starter motor from bellhousing. Set aside in safe location to prevent damage.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
6. 6

   Access torque converter bolts
   Remove lower inspection cover from bellhousing to access torque converter bolts. Mark torque converter position relative to flexplate with paint pen. Rotate crankshaft using 22mm socket on crankshaft bolt to access each torque converter bolt through inspection opening. Remove all torque converter bolts and push converter back into transmission to disengage from flexplate.
   ⚠Do not allow torque converter to fall out of transmission during removal. Converter must remain fully seated in transmission pump.
   Torque spec

   Cover Bolts16 Nm (12 lb-ft)

   Torque Converter Bolts50 Nm (37 lb-ft)
7. 7

   Remove transmission from engine
   Remove all transmission-to-engine mounting bolts, noting different lengths and locations for reassembly. Carefully pull transmission straight back from engine using transmission jack. Maintain level orientation to prevent torque converter from sliding out. Continue pulling back until transmission input shaft clears engine. Lower transmission and remove from under vehicle.
   ⚠️Have assistant guide transmission during removal. Transmission must move straight back to avoid damaging input shaft, pilot bearing, or torque converter.
   Torque spec

   Transmission-to-Engine Bolts55 Nm (41 lb-ft)
8. 8

   Lock crankshaft and remove flexplate
   Install flywheel holding tool to lock crankshaft from rotation. If holding tool is unavailable, wedge large screwdriver between flexplate teeth and bellhousing. Mark flexplate orientation to crankshaft with paint or punch mark for reinstallation in same position. Remove all flexplate bolts in cross pattern using breaker bar. Remove flexplate from crankshaft flange and inspect for cracks, heat damage, or damaged ring gear teeth.
   ℹ️Flexplate bolts typically use thread locker and may require significant force to break loose.
   Torque spec

   Flexplate Bolts85 Nm (63 lb-ft)
9. 9

   Inspect and clean mounting surfaces
   Inspect crankshaft flange for cracks, wear, or damage. Check pilot bearing condition if equipped. Clean all thread holes in crankshaft flange using appropriate tap or thread chaser. Clean mounting surface with brake cleaner and lint-free cloth. Ensure all old thread locker residue is removed from bolt holes and crankshaft flange.
10. 10

    Install new flexplate
    Align new flexplate to crankshaft flange matching orientation marks from removal or ensuring dowel pins engage properly. Apply medium-strength thread locker to new flexplate bolt threads. Start all flexplate bolts by hand to ensure proper thread engagement. Install flywheel holding tool to prevent rotation. Torque flexplate bolts to specification in star pattern, working from center outward in multiple passes.
    ⚠Consult factory service manual for exact tightening sequence. Improper torque sequence can cause flexplate cracking or bolt failure.
    Torque spec

    Flexplate Bolts85 Nm (63 lb-ft)
11. 11

    Reinstall transmission
    Verify torque converter is fully seated in transmission by measuring distance from bellhousing face to converter mounting ears. Should be approximately 1 inch recessed. Apply thin film of high-temp grease to torque converter pilot hub. Position transmission on jack and raise into position. Align transmission with engine ensuring dowel pins engage properly. Install transmission-to-engine bolts and torque to specification in cross pattern.
    ⚠️Transmission input shaft must slide smoothly into torque converter. Never force transmission using bolts to pull it into place.
    Torque spec

    Transmission-to-Engine Bolts55 Nm (41 lb-ft)
12. 12

    Install torque converter to flexplate
    Align torque converter to flexplate matching marks made during disassembly. Rotate crankshaft to access each bolt hole through inspection opening. Apply medium-strength thread locker to torque converter bolt threads. Install all torque converter bolts hand-tight first. Torque bolts to specification following service manual sequence while rotating crankshaft for access. Install inspection cover with new gasket if required.
    Torque spec

    Torque Converter Bolts50 Nm (37 lb-ft)

    Cover Bolts16 Nm (12 lb-ft)

    Gasket Bolts20 Nm (15 lb-ft)
13. 13

    Reinstall starter and transmission mounting
    Install starter motor into bellhousing and torque mounting bolts to specification. Reconnect starter electrical connections ensuring proper terminal orientation. Raise transmission with jack and install crossmember. Torque crossmember mounting bolts to specification. Remove transmission jack once crossmember is secure.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
14. 14

    Reconnect drivelines and complete assembly
    Reconnect front and rear driveshafts aligning marks made during removal. Torque driveshaft bolts to specification. Reconnect all transmission electrical connectors, shift cable, and cooler lines. Refill transfer case with specified fluid to proper level. Reinstall exhaust system and torque all connections to specification. Remove engine support bar. Install under covers and wheels.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
15. 15

    Refill transmission fluid and bleed system
    Fill transmission through dipstick tube or fill port with specified Hyundai SP-IV-M ATF. Start with approximately 8 quarts. Start engine and allow to idle. Shift through all gear ranges with foot on brake, pausing 2-3 seconds in each position. Return to Park and check fluid level with engine running at operating temperature. Add fluid as needed to bring to proper level between MIN and MAX marks.
    ⚠Overfilling transmission can cause foaming and damage. Add fluid gradually and check level frequently.

Reassembly

1. Torque all fasteners to specified values using proper sequence for critical components
2. Double-check all electrical connections are fully seated and secured
3. Verify all cooler lines are properly connected and secured with clips
4. Ensure driveshaft alignment marks match original positions for proper balance
5. Reconnect battery negative cable last after all other connections are complete

Verification

• Start engine and verify no abnormal noises from bellhousing area
• Check for fluid leaks around transmission pan, cooler lines, and all connections
• Test drive vehicle through all gear ranges verifying smooth shifting and engagement
• Listen for any rattling or knocking noises during acceleration and deceleration that could indicate loose flexplate or torque converter
• Verify no vibration at idle or during driving that could indicate flexplate imbalance
• Recheck transmission fluid level after test drive with engine at operating temperature
• Scan for diagnostic trouble codes and verify no transmission-related codes are present

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