This procedure covers the removal and replacement of the rear wheel knuckle/spindle assembly on a 2016-2024 Hyundai Tucson with 2.5L I4 AWD, including disconnection of the hub, brake components, and suspension connections.

Warnings

Tools required

Parts

• Rear wheel knuckle/spindle assembly × 1 — Use OEM specification
• Ball joint castle nut × 1 — Use OEM specification
• Cotter pin for ball joint × 1 — Use OEM specification
• Brake fluid (if bleeding required) × 1 — DOT 4

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen rear wheel lug nuts while vehicle is on ground (do not remove)
3. Raise rear of vehicle and support securely on jack stands at manufacturer-specified lift points
4. Remove rear wheel completely
5. Spray all fasteners with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Remove brake caliper and rotor
   Remove the brake caliper mounting bolts and slide the caliper off the rotor. Support the caliper with wire or bungee cord from the suspension—never let it hang by the brake hose. Remove the rotor retaining screw (if equipped) and slide the rotor off the hub.
2. 2

   Disconnect parking brake cable
   Release the parking brake cable from the backing plate or caliper bracket. Depress the cable retaining tabs and slide the cable out of its mounting bracket. Note the routing for reinstallation.
3. 3

   Disconnect ABS wheel speed sensor
   Locate the ABS wheel speed sensor connector near the knuckle. Disconnect the electrical connector and remove the sensor mounting bolt. Carefully extract the sensor from the knuckle, noting its orientation. Do not damage the sensor tip or tone ring.
4. 4

   Remove strut-to-knuckle bolts
   Support the knuckle assembly with a floor jack placed under the lower control arm. Remove the two bolts connecting the strut assembly to the rear knuckle. These are large diameter bolts passing through the knuckle. The knuckle will now be free to pivot at the control arm connection.
   ⚠Support the knuckle with a jack before removing these bolts to prevent sudden dropping of the assembly.
   Torque spec

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

   Disconnect sway bar link (if applicable)
   If the sway bar link attaches to the knuckle or lower control arm, disconnect it by removing the lower nut. Hold the ball stud shaft with an Allen key to prevent spinning while loosening the nut.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
6. 6

   Separate ball joint from knuckle
   Remove the cotter pin from the ball joint castle nut. Loosen and remove the ball joint nut connecting the lower control arm to the knuckle. Use a ball joint separator or pickle fork to break the taper connection between the ball joint stud and knuckle. Apply force carefully to avoid damaging the ball joint boot if reusing.
   ⚠Using a pickle fork will likely damage the ball joint boot. Use a proper ball joint separator if reusing components.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
7. 7

   Remove hub/bearing assembly from knuckle
   If transferring the hub and bearing to the new knuckle, remove the hub mounting bolts from the rear of the knuckle (typically 4 bolts accessible from the back side). Carefully tap the hub assembly out of the knuckle using a soft-faced hammer or press if necessary. Inspect the bearing for wear, noise, or roughness.
8. 8

   Remove knuckle from vehicle
   With all connections separated, remove the rear knuckle assembly from the vehicle. Inspect all mounting surfaces, bushings, and connection points on the new knuckle for damage or defects before installation.
9. 9

   Install hub/bearing into new knuckle
   Clean the hub bore in the new knuckle thoroughly. Install the hub and bearing assembly into the new knuckle, ensuring proper seating. Install and evenly tighten the hub mounting bolts in a star pattern to ensure square installation. Verify the hub rotates freely without binding.
10. 10

    Install knuckle and connect ball joint
    Position the new knuckle assembly onto the vehicle. Insert the lower control arm ball joint stud into the knuckle. Install a new castle nut and torque to specification. Align the castle nut slots with the ball stud hole and install a new cotter pin. Bend the cotter pin ends to secure.
    ℹ️Never loosen the nut to align cotter pin holes. If slots don't align, tighten further until alignment is achieved.
    Torque spec

    Ball Joint Nut88 Nm (65 lb-ft)
11. 11

    Reconnect strut to knuckle
    Raise the knuckle assembly using the floor jack to align the strut bolt holes. Install the strut-to-knuckle bolts and torque to specification. Ensure the bolts are fully seated and threads are not cross-threaded.
    Torque spec

    Strut Bolts115 Nm (85 lb-ft)
12. 12

    Reconnect sway bar link
    If disconnected, reconnect the sway bar link to the knuckle or control arm. Hold the ball stud with an Allen key and torque the nut to specification.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
13. 13

    Install ABS sensor and parking brake
    Install the ABS wheel speed sensor into the knuckle, ensuring proper orientation and seating. Connect the electrical connector. Reinstall the parking brake cable following the original routing and secure all retaining clips.
14. 14

    Install brake rotor and caliper
    Slide the brake rotor onto the hub and install the retaining screw if equipped. Position the brake caliper over the rotor and install the caliper mounting bolts to specification. Pump the brake pedal several times to restore caliper piston position.
15. 15

    Install wheel and perform final torque
    Install the wheel and hand-tighten the lug nuts in a star pattern. Lower the vehicle until the tire just contacts the ground. Torque the wheel lug nuts to specification in a star pattern. Fully lower the vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. After initial test drive, re-torque all critical fasteners including ball joint nut, strut bolts, and wheel lug nuts
2. Verify parking brake operates correctly and holds the vehicle on an incline
3. Check for any unusual noises from the rear suspension during initial driving

Verification

• Test drive the vehicle and verify no abnormal noises, vibrations, or pulling from the rear suspension
• Verify ABS warning light is off and wheel speed sensor is functioning properly
• Check brake operation and ensure firm pedal feel with no leaks
• Perform a four-wheel alignment to verify rear toe, camber, and overall suspension geometry
• Visually inspect all connections and torque settings after 50-100 miles of driving

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