This procedure covers the removal and replacement of the front steering knuckle/spindle assembly on a 2016-2024 Hyundai Tucson with the 2.5L I4 AWD engine.

Warnings

Tools required

Parts

• Front steering knuckle assembly × 1 — Use OEM specification
• Hub bearing (if integrated with knuckle) × 1 — Typically included with knuckle assembly
• Front axle hub nut × 1 — One-time use fastener
• Ball joint cotter pin × 1 — Use OEM specification
• Brake caliper bracket bolts (if corroded) × 2 — Use OEM specification
• Thread locker compound × 1 — Medium strength

Preparation

1. Park vehicle on level ground 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. With vehicle still on ground, have assistant apply brakes while you loosen (but do not remove) the front axle hub nut with 32mm socket and breaker bar
5. Raise front of vehicle with floor jack and support securely on jack stands at designated lift points
6. Remove wheel completely
7. Spray all fasteners with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Remove brake caliper and rotor
   Remove the two brake caliper bracket mounting bolts from the rear of the knuckle. Remove the caliper and bracket as an assembly. Support the caliper with a wire hook or bungee cord to prevent strain on the brake hose. Remove the brake rotor by pulling straight off the hub. If stuck, use two M8 threaded holes in rotor to push it off with bolts.
2. 2

   Disconnect ABS wheel speed sensor
   Locate the ABS wheel speed sensor connector near the strut assembly. Disconnect the electrical connector by pressing the release tab. Remove the sensor mounting bolt from the knuckle and carefully extract the sensor from its bore in the knuckle. Set aside to prevent damage.
   Torque spec

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

   Remove tie rod end from knuckle
   Remove the cotter pin from the tie rod end castle nut. Loosen and remove the tie rod end castle nut. Use a ball joint separator or pickle fork to separate the tie rod end from the knuckle steering arm. Do not damage the tie rod end boot. Count and record the number of exposed threads on the tie rod for reassembly reference.
   ⚠Apply force gradually when using the ball joint separator to prevent sudden release and tool slippage.
4. 4

   Disconnect sway bar link
   Locate the sway bar end link where it connects to the lower control arm or knuckle. Hold the shaft with an Allen key to prevent spinning. Remove the upper nut connecting the sway bar link to the strut or knuckle assembly. Swing the link out of the way.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
5. 5

   Separate lower ball joint from knuckle
   Remove the cotter pin from the lower ball joint castle nut. Loosen but do not fully remove the ball joint nut (leave it threaded on a few turns to prevent sudden separation). Use a ball joint separator or pickle fork to break the taper between the ball joint stud and knuckle. Once separated, remove the nut completely and lower the control arm away from the knuckle.
   ⚠Keep the ball joint nut threaded on loosely during initial separation to catch the knuckle when the taper breaks free.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
6. 6

   Remove strut-to-knuckle pinch bolts
   Locate the two large bolts securing the knuckle to the strut assembly. These bolts pass through a pinch clamp on the knuckle. Remove both bolts completely. You may need to spread the pinch clamp slightly with a pry bar or large screwdriver to break the friction fit. Note the orientation of any alignment cams or eccentric washers if present.
   Torque spec

   Strut Bolts115 Nm (85 lb-ft)
7. 7

   Remove axle hub nut and extract CV axle
   Fully remove the front axle hub nut that was previously loosened. Pull the knuckle assembly outward while simultaneously pushing the CV axle shaft inward toward the transmission. If the CV axle splines are stuck in the hub bearing, use a hub puller or slide hammer with appropriate adapter to press the axle out of the hub. Support the CV axle and tie it up out of the way to prevent damage to the inner CV joint boot.
   ⚠Do not allow the CV axle to hang unsupported as this can damage the inner CV joint and boot.
8. 8

   Remove knuckle from vehicle
   With all connections separated, carefully maneuver the knuckle assembly out of the strut bracket and away from the vehicle. The knuckle should now be completely free. Inspect the mounting surfaces and clean with a wire brush if corrosion is present.
9. 9

   Prepare new knuckle for installation
   Clean all mating surfaces on the strut, control arm, and tie rod. Compare the new knuckle to the old unit to verify correct part. If the hub bearing is not pre-installed in the new knuckle, press or drive it in according to manufacturer specifications. Apply a thin coat of anti-seize to the CV axle splines and hub bearing bore.
10. 10

    Install knuckle to strut assembly
    Position the new knuckle onto the strut assembly, aligning the pinch clamp. Insert the CV axle shaft through the hub bearing until it seats. Install the strut-to-knuckle bolts with any alignment cams in their original positions. Torque the bolts to specification but do not fully tighten until the knuckle is supported by the ball joint.
    Torque spec

    Strut Bolts115 Nm (85 lb-ft)
11. 11

    Connect lower ball joint
    Raise the lower control arm to align the ball joint stud with the hole in the knuckle. Insert the ball joint stud into the knuckle and install the new castle nut. Torque the ball joint nut to specification. Install a new cotter pin through the castle nut and ball joint stud, bending the ends to secure.
    Torque spec

    Ball Joint Nut88 Nm (65 lb-ft)
12. 12

    Reconnect tie rod end
    Insert the tie rod end stud into the knuckle steering arm. Install the castle nut and torque to specification (refer to suspension repair manual for tie rod torque value). Install a new cotter pin and bend to secure. Verify tie rod length matches the measurement taken during disassembly.
13. 13

    Reconnect sway bar link and ABS sensor
    Connect the sway bar link to the knuckle or strut. Hold the shaft with an Allen key and torque the nut to specification. Install the ABS wheel speed sensor into the knuckle bore and secure with the mounting bolt. Connect the ABS sensor electrical connector until it clicks.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)

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

    Install brake rotor and caliper
    Slide the brake rotor onto the hub. Install the brake caliper and bracket assembly onto the knuckle. Install the caliper bracket mounting bolts and torque to specification (typically 95-110 Nm but verify in brake service manual). Ensure the brake pads are properly seated.
15. 15

    Install axle hub nut and wheel
    Install the new axle hub nut onto the CV axle shaft. Hand-tighten only at this stage. Install the wheel and thread the lug nuts on by hand. Lower the vehicle until the tire just touches the ground (weight not fully on suspension). Have an assistant apply the brakes firmly. Torque the axle hub nut to specification (typically 240-260 Nm for this model). Raise the vehicle slightly and torque all wheel lug nuts to specification in a star pattern. Lower vehicle completely to the ground.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. After initial test drive, re-torque all fasteners to specification
2. The vehicle MUST have a four-wheel alignment performed after knuckle replacement to restore proper steering geometry and prevent tire wear
3. Check brake pedal feel and pump several times before driving to ensure proper caliper piston positioning

Verification

• Verify all fasteners are torqued to specification with no loose components
• Spin the wheel by hand to ensure the hub bearing rotates smoothly without binding or noise
• Check that the ABS warning light is not illuminated on the dashboard
• Test drive at low speed and verify proper steering response and no unusual noises from the front suspension
• Schedule four-wheel alignment within 24 hours of completing this repair

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