Complete replacement of both front strut assemblies on a 2016-2024 Hyundai Tucson with 2.5L AWD engine, including removal of strut-to-knuckle connection and upper strut tower mounting.

Warnings

Tools required

Parts

• Front strut assembly (complete with spring) × 2 — Use OEM specification or quality aftermarket (KYB, Monroe)
• Strut tower mounting nuts (reuse if not damaged) × 6 — Inspect before ordering
• Strut-to-knuckle bolts and nuts × 4 — Replace recommended

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
4. Raise front of vehicle and support securely on jack stands positioned on frame rails or specified jacking points
5. Remove both front wheels completely
6. Spray penetrating oil on strut-to-knuckle bolts, sway bar link nuts, and strut tower nuts (allow to soak)
7. Open hood and locate strut tower access (remove plastic cowl cover below windshield if necessary for access)

Procedure

1. 1

   Disconnect sway bar link from strut
   Locate the sway bar end link connection to the strut. Insert an Allen key into the shaft of the sway bar link to prevent it from spinning. Using a wrench on the nut, loosen and remove the sway bar link upper nut. Swing the link away from the strut or let it hang. Repeat for opposite side.
   ℹ️If link spins freely despite holding shaft, the ball joint may be worn. Consider replacing sway bar links.
   Torque spec

   Sway Bar Link61 Nm (45 lb-ft)
2. 2

   Remove brake line bracket from strut
   Locate the brake line bracket attached to the strut housing (typically one bolt or clip). Remove the fastener and carefully separate the brake line from the strut. Do not allow brake line to hang unsupported - use wire or zip ties to secure it to prevent strain on the line.
   ⚠Do not kink, twist, or place tension on brake lines. Damage to brake lines can cause brake failure.
3. 3

   Disconnect ABS wheel speed sensor wire
   Locate the ABS sensor wire routing clips or brackets attached to the strut housing. Carefully unclip or unbolt the wire from the strut, ensuring the wire remains connected to the sensor at the wheel hub. Allow wire to hang safely without tension.
4. 4

   Remove strut-to-knuckle bolts
   Locate the two bolts connecting the bottom of the strut to the steering knuckle (these are large diameter bolts going through the knuckle). Support the knuckle assembly with a jack or secure it to prevent dropping. Use a breaker bar and socket to remove both bolts completely. Note the orientation of any alignment marks or eccentric washers. You may need to tap the bolts out with a brass hammer.
   ⚠Strut-to-knuckle bolts are CRITICAL fasteners. Replace if threads are damaged. These bolts control wheel alignment camber adjustment.
   Torque spec

   Strut Bolts115 Nm (85 lb-ft)
5. 5

   Separate strut from knuckle
   With bolts removed, use a pry bar or carefully spread the knuckle fork to separate the strut from the knuckle. The strut shaft will slide out of the knuckle mounting bracket. If seized, apply additional penetrating oil and use controlled force with a pry bar. Support the knuckle assembly to prevent it from falling or straining the CV axle.
   ⚠Do not allow knuckle/hub assembly to hang by CV axle or brake line. Support with jack stand or wire.
6. 6

   Access and remove strut tower mounting nuts
   From under the hood, locate the three strut tower mounting nuts (visible at the top of the strut tower in the engine bay). These nuts secure the top strut mount to the vehicle body. While supporting the strut from below (use assistant or position jack under strut), remove all three nuts completely. On some models, a plastic cap covers the center nut.
   ⚠️Strut must be supported from below before removing upper mounting nuts. Strut assembly is heavy and will fall if not supported.
   Torque spec

   Strut Tower Nuts50 Nm (37 lb-ft)
7. 7

   Remove strut assembly from vehicle
   With upper nuts removed and strut disconnected from knuckle, carefully lower and maneuver the complete strut assembly out through the wheel well. Angle the assembly as needed to clear the fender and control arms. Set old strut aside. Repeat steps 1-7 for opposite side.
8. 8

   Prepare new strut assembly
   Unpack new strut assembly and verify it matches the old unit (overall length, mounting configuration, spring seat orientation). If strut has shipping locks or pins, remove them per manufacturer instructions. Verify the top mount is properly oriented with the studs matching the vehicle's tower bolt pattern.
   ℹ️Some struts ship with temporary locks holding the shaft compressed. Remove these before installation.
9. 9

   Install new strut into strut tower
   Lift the new strut assembly into position through the wheel well, aligning the upper mount studs with the three holes in the strut tower. Push the strut up until the mount contacts the tower. From under the hood, thread on the three strut tower nuts by hand. Do not fully tighten yet - snug only to hold the strut in place.
10. 10

    Connect strut to steering knuckle
    Maneuver the steering knuckle assembly to align with the lower strut mounting bracket. You may need to use a pry bar or jack to position the knuckle correctly. Insert the two strut-to-knuckle bolts through the knuckle and strut. If your bolts have alignment cams or eccentric washers, orient them to match the original position (mark with paint if needed). Thread nuts onto bolts but do not fully tighten yet.
11. 11

    Torque strut tower mounting nuts
    From under the hood, torque the three strut tower mounting nuts to specification in a star pattern to ensure even loading of the mount. Use a torque wrench and verify each nut reaches the specified torque.
    ⚠️CRITICAL TORQUE SPECIFICATION: Under-torquing can allow strut to separate from vehicle. Over-torquing can strip threads or crack strut tower.
    Torque spec

    Strut Tower Nuts50 Nm (37 lb-ft)
12. 12

    Torque strut-to-knuckle bolts
    Using a torque wrench, torque both strut-to-knuckle bolts to the specified value. These bolts are critical for suspension integrity and wheel alignment. Verify both bolts are properly seated and torqued.
    ⚠️CRITICAL TORQUE SPECIFICATION: These bolts determine camber alignment and structural connection. Improper torque can cause wheel misalignment or separation.
    Torque spec

    Strut Bolts115 Nm (85 lb-ft)
13. 13

    Reconnect brake line and ABS sensor wire
    Reattach the brake line bracket to the strut housing using the original fastener. Ensure the brake line is properly routed and not kinked or stretched. Reclip or rebolt the ABS sensor wire to the strut housing, following the original routing path. Verify no wires or hoses are pinched or at risk of contact with rotating components.
14. 14

    Reconnect sway bar end link
    Position the sway bar end link ball stud into the strut mounting hole. Install the nut and use an Allen key to hold the shaft while torquing the nut to specification.
    Torque spec

    Sway Bar Link61 Nm (45 lb-ft)
15. 15

    Install wheels and lower vehicle
    Reinstall both front wheels and thread lug nuts by hand. Lower the vehicle until tires just contact the ground but vehicle weight is still on jack stands. Torque wheel lug nuts in a star pattern to specification. Fully lower vehicle and remove jack stands. Perform final torque verification of lug nuts with vehicle on ground.
    ⚠️CRITICAL: Wheel lug nuts must be torqued in star pattern to prevent wheel detachment and to avoid warping brake rotors.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Verify all fasteners have been torqued to specification using a calibrated torque wrench
2. Reinstall any plastic cowl covers or trim panels removed for strut tower access
3. Check that no tools or parts were left in the engine bay or wheel wells
4. Repeat entire procedure for opposite side if only one side was completed

Verification

• Start vehicle and turn steering wheel full lock left and right while stationary - listen for any unusual noises, binding, or rubbing
• Test drive vehicle at low speed in safe area - verify steering response feels normal and no pulling occurs
• Check for fluid leaks around brake lines that were disturbed
• MANDATORY: Schedule professional front wheel alignment immediately - strut replacement affects camber, caster, and toe settings
• After 50-100 miles, re-torque all strut mounting fasteners and wheel lug nuts to verify they have not loosened
• Monitor tire wear pattern over next 500 miles to confirm proper alignment was achieved

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