Remove and replace the automatic locking hub assembly on the front axle of a 2016-2024 Hyundai Tucson 2.5L AWD.

Warnings

Tools required

Parts

• Automatic locking hub assembly × 1 — Use OEM specification
• Axle nut cotter pin or staking type axle nut × 1 — Use OEM specification
• Hub mounting bolt set (if reuse not recommended) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Loosen wheel lug nuts on the side being serviced while vehicle is on ground
4. Loosen (but do not remove) the front axle nut while vehicle is on ground with brakes applied - this nut requires significant torque
5. Raise front of vehicle and support securely on jack stands at manufacturer-specified lift points
6. Remove wheel and tire assembly
7. Clean the work area around the hub and axle with brake cleaner to prevent contamination

Procedure

1. 1

   Remove axle nut completely
   With the vehicle raised and wheel removed, completely remove the front axle nut that was previously loosened. Remove and discard the cotter pin if equipped, or note if nut is staked type. Set aside the nut as it should be replaced with a new one during reassembly.
2. 2

   Disconnect brake caliper (if access required)
   Depending on hub access, you may need to remove the brake caliper. Remove caliper mounting bolts and support the caliper with wire or a bungee cord - do not let it hang by the brake hose. The rotor can typically remain in place but may be removed for better access.
3. 3

   Remove locking hub cover screws
   Locate the cover screws on the face of the automatic locking hub assembly. These are typically small screws around the perimeter of the hub cap. Remove all cover screws using the appropriate tool, keeping them organized for reinstallation.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
4. 4

   Remove locking hub cover
   Carefully remove the locking hub cover from the hub body. You may need to gently tap with a rubber mallet or use a flat pry tool at designated pry points. Inspect the cover gasket or O-ring and replace if damaged.
5. 5

   Remove hub mounting bolts
   Locate and remove the mounting bolts that secure the automatic locking hub assembly to the wheel hub. These bolts typically thread into the hub from the front. Keep bolts organized and inspect threads for damage.
   Torque spec

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

   Remove locking hub assembly
   Carefully pull the automatic locking hub assembly straight off the axle shaft and hub. The assembly should slide off the splined axle shaft. If stuck, gently tap with a rubber mallet while pulling evenly. Do not pry against the hub surface.
7. 7

   Clean mounting surfaces
   Thoroughly clean the hub mounting surface, axle splines, and mating surfaces with brake cleaner and a wire brush. Remove all old grease, dirt, and corrosion. Inspect the axle splines for wear or damage. Check the wheel hub bearing surface for any damage or excessive wear.
8. 8

   Install new locking hub assembly
   Apply a thin coat of anti-seize to the axle splines (avoid getting on bearing surfaces). Align the new automatic locking hub assembly with the axle splines and hub mounting holes. Slide the assembly onto the axle shaft, ensuring proper spline engagement. The hub should seat flush against the wheel hub face.
9. 9

   Install and torque mounting bolts
   Install the hub mounting bolts and hand-tighten in a star pattern to ensure even seating. Using a torque wrench, tighten the mounting bolts to specification in multiple passes, working in a star pattern to prevent warping or uneven loading of the hub assembly.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
10. 10

    Install locking hub cover
    Install a new gasket or O-ring onto the hub cover if equipped. Position the cover onto the hub body, ensuring proper alignment with screw holes. Press the cover into place ensuring it seats completely and evenly around the perimeter.
11. 11

    Install and torque cover screws
    Install all cover screws and hand-tighten. Torque the cover screws to specification in a cross pattern to ensure even clamping force and proper sealing. Do not overtighten as this can strip the threads or crack the cover.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)
12. 12

    Reinstall brake components
    If the brake caliper was removed, reinstall it over the rotor and torque the caliper mounting bolts to specification. Ensure brake pads are properly seated and the caliper slides freely.
13. 13

    Install and torque axle nut
    Install a NEW axle nut onto the CV axle shaft. Torque the axle nut to specification. If using a cotter pin type nut, align the slots with the hole in the axle shaft and install a new cotter pin, bending the ends properly. If using a staking type nut, use a punch to stake the nut collar into the axle shaft groove at the designated points.
    ⚠Always use a NEW axle nut. Never reuse the old nut as it is a critical safety component.
    Torque spec

    Axle Nut250 Nm (184 lb-ft)
14. 14

    Reinstall wheel and torque lug nuts
    Install the wheel and tire assembly. Hand-tighten all lug nuts in a star pattern. Lower the vehicle until the tire just contacts the ground (still partially supported). Torque the wheel lug nuts to specification using a star pattern. Fully lower the vehicle and perform a final torque check on lug nuts.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification in the correct sequence
2. Verify the axle nut is properly secured with a new cotter pin or properly staked
3. Double-check that brake components are properly installed and caliper moves freely
4. Perform final torque check on wheel lug nuts after lowering vehicle completely

Verification

• Test drive the vehicle at low speed in a safe area and verify no unusual noises from the hub area
• Engage and disengage AWD system (if manually selectable) and verify proper operation
• Drive in a figure-8 pattern in both directions to verify hub locks and unlocks properly during turns
• After test drive, recheck wheel lug nut torque and axle nut security
• Inspect for any fluid leaks around the hub assembly
• Listen for clicking, grinding, or binding noises that could indicate improper installation

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