This procedure covers the removal and installation of the manual locking hub assembly on the front axle of a 2016-2024 Hyundai Tucson with the 2.5L I4 AWD system.

Warnings

Tools required

Parts

• Manual locking hub assembly × 1 — Use OEM specification
• Hub gasket or O-ring (if equipped) × 1 — Usually included with hub assembly
• Cotter pin or axle nut (if staked type) × 1 — Use OEM specification
• Cover screws (if damaged) × 6 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen front wheel lug nuts while vehicle is on the ground (do not remove)
3. Raise front of vehicle and support securely on jack stands at manufacturer-specified lift points
4. Remove front wheel completely
5. Verify the hub type - manual locking hubs are not standard equipment on this vehicle and may be aftermarket

Procedure

1. 1

   Remove locking hub cover
   Rotate the locking hub dial to the 'FREE' or unlocked position. Remove the cover screws (typically 6 screws) securing the locking hub cover to the hub body. Carefully remove the cover and set aside with screws. Inspect the gasket or O-ring for damage.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
2. 2

   Remove hub mechanism
   Remove the internal snap ring that retains the locking mechanism if present. Carefully extract the locking hub mechanism, being careful not to lose any small springs, detent balls, or pawls. Note the orientation of all components for reassembly. Clean all parts with brake cleaner and inspect for wear.
   ⚠Small springs and detent components can launch when removing the mechanism. Work slowly and be prepared to catch loose parts.
3. 3

   Remove axle nut
   If the axle nut uses a cotter pin, remove and discard it. If the nut is staked, use a hammer and punch to unstake the collar. Have an assistant apply the brakes or insert a pry bar through the brake rotor to prevent the hub from rotating. Use a breaker bar and appropriate socket to loosen the axle nut. Remove the nut completely and set aside (do not reuse if staked type).
   ⚠The axle nut requires significant torque to remove. Ensure the vehicle is stable and the hub is properly braced before applying force.
   Torque spec

   Axle Nut250 Nm (184 lb-ft)
4. 4

   Remove locking hub body mounting bolts
   Locate the mounting bolts that secure the locking hub body to the wheel hub (typically 4-6 bolts around the perimeter). Remove all mounting bolts and set aside. If the locking hub body is stubborn, gently tap around the edges with a rubber mallet to break the seal.
   Torque spec

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

   Remove locking hub assembly
   Carefully pull the locking hub assembly straight off the axle shaft and wheel hub. If it resists, use a pry bar gently between the hub body and wheel hub to break it free. Inspect the splines on both the axle shaft and inside the hub for wear, damage, or debris. Clean all surfaces with brake cleaner and a wire brush.
   ℹ️Do not pry against the brake rotor or caliper. Apply pressure only to the hub assembly itself.
6. 6

   Inspect mating surfaces
   Thoroughly clean the wheel hub face, axle shaft splines, and all mounting surfaces. Remove any old gasket material, corrosion, or debris. Inspect the axle shaft threads for damage. Apply a light coat of anti-seize to the axle shaft splines (avoid getting any on the threads where the nut will tighten).
7. 7

   Install new locking hub body
   Install a new gasket or O-ring onto the locking hub body if equipped. Align the splines of the new locking hub assembly with the axle shaft splines. Carefully slide the hub body onto the axle shaft, ensuring it seats fully against the wheel hub face. Verify the gasket is properly positioned.
   ⚠Ensure the hub is fully seated before installing bolts. A partially seated hub will cause binding and premature wear.
8. 8

   Install mounting bolts
   Install all mounting bolts finger-tight first to ensure proper alignment. Tighten the mounting bolts in a crisscross pattern to the specified torque of 27 Nm (20 lb-ft). Verify the hub body is seated evenly around its entire circumference.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
9. 9

   Install axle nut
   Install a new axle nut (if staked type) or the existing nut (if cotter pin type) onto the axle shaft threads. Have an assistant apply the brakes or use a pry bar through the rotor to prevent rotation. Torque the axle nut to 250 Nm (184 lb-ft) using a calibrated torque wrench. If using a cotter pin type, install a new cotter pin and bend the ends. If using a staked type, stake the nut collar into the axle shaft groove using a hammer and punch.
   ⚠Proper axle nut torque is critical for bearing life and safety. Always use a calibrated torque wrench and verify final torque.
   Torque spec

   Axle Nut250 Nm (184 lb-ft)
10. 10

    Install hub mechanism and cover
    Lubricate the locking mechanism components with a light grease if specified by the hub manufacturer. Install the hub mechanism into the hub body, ensuring all springs, detent balls, and pawls are properly positioned. Install the internal snap ring if equipped. Place the gasket onto the cover, position the cover over the hub body, and install all cover screws. Tighten cover screws in a crisscross pattern to 11 Nm (8 lb-ft).
    Torque spec

    Cover Screws11 Nm (8 lb-ft)
11. 11

    Test hub operation
    Rotate the locking hub dial from 'FREE' to 'LOCK' position several times, verifying smooth operation and positive engagement. The hub should click or snap into each position. Rotate the brake rotor by hand to ensure there is no binding or resistance when in the 'FREE' position.
12. 12

    Reinstall wheel
    Clean the wheel mounting surface on the hub. Install the wheel and thread lug nuts by hand. Lower the vehicle until the tire just touches the ground but the suspension is not loaded. Torque the lug nuts in a star pattern to 140 Nm (103 lb-ft). Fully lower the vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Torque all fasteners to the specified values in the proper sequence
2. Always use a new cotter pin or new axle nut if the staked type is used
3. Ensure the hub mechanism operates smoothly before final assembly
4. Clean all mounting surfaces thoroughly before installation to prevent leaks

Verification

• Test drive the vehicle in both 2WD (hub in 'FREE') and 4WD (hub in 'LOCK') positions to verify proper operation
• Listen for any unusual noises from the hub area during turns and acceleration
• After 50-100 miles, re-check the axle nut torque and lug nut torque
• Verify no fluid leaks around the hub assembly
• Confirm smooth engagement and disengagement of the locking mechanism

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