This procedure covers removal and replacement of the front lower control arm on a 2016-2024 Hyundai Tucson with the 2.5L I4 AWD engine, including ball joint separation and proper torque sequencing.

Warnings

Tools required

Parts

• Front lower control arm (left or right as needed) × 1 — Use OEM specification
• Ball joint castle nut (if not reusable) × 1 — Use OEM specification

Preparation

1. Park vehicle on level 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 on jack stands at manufacturer lift points
5. Remove front wheel on side being serviced
6. Spray all control arm fasteners with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Support the lower control arm
   Position a floor jack under the lower control arm ball joint area to support the arm and take tension off the fasteners. Raise jack until it just contacts the arm but does not lift the vehicle.
2. 2

   Remove ball joint castle nut
   Remove the cotter pin from the ball joint castle nut. Using a 19mm socket, remove the ball joint nut completely. Keep the nut if it is in good condition with intact castellations, otherwise replace with new.
   ⚠Do not reuse cotter pin. Always install a new cotter pin during reassembly.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
3. 3

   Separate ball joint from knuckle
   Using a ball joint separator tool or pickle fork, separate the ball joint stud from the steering knuckle. Insert the tool between the control arm and knuckle, then strike or tighten to pop the taper loose. Once free, lower the floor jack slightly to allow the control arm to drop away from the knuckle.
   ⚠Pickle fork tools will damage ball joint boots. Use only if replacing control arm. For ball joint preservation, use a proper separator tool.
4. 4

   Remove rear control arm mounting bolt
   Locate the rear control arm mounting bolt that connects to the subframe. Using an 18mm socket and breaker bar, remove the rear bolt completely. This bolt may be very tight. Note the orientation of any washers or bushings for reinstallation.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
5. 5

   Remove front control arm mounting bolt
   Locate the front control arm mounting bolt that connects to the subframe. Using an 18mm socket and breaker bar, remove the front bolt completely. Support the control arm as you remove this final bolt to prevent it from dropping.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
6. 6

   Remove control arm from vehicle
   With both mounting bolts removed and ball joint separated, carefully remove the control arm from the vehicle. Maneuver it out from between the subframe and steering knuckle. Inspect the old arm for wear patterns and compare with replacement part.
7. 7

   Prepare new control arm and mounting points
   Clean the subframe mounting bolt holes with a wire brush to remove rust and debris. Inspect the ball joint boot on the new control arm for damage. Ensure all bushings are properly seated in the new control arm. Compare new arm with old to verify correct part.
8. 8

   Install new control arm
   Position the new control arm into place between the subframe and knuckle area. Align the mounting holes with the subframe. Insert the front and rear mounting bolts by hand, threading them in several turns but do not tighten yet. The bolts should thread in smoothly without forcing.
9. 9

   Connect ball joint to knuckle
   Raise the floor jack under the control arm to lift the ball joint stud into the steering knuckle hole. Align the stud with the hole and push upward until fully seated. Install the castle nut and hand-tighten. Using a 19mm socket and torque wrench, tighten to specification. Align the next castle slot with the cotter pin hole and install a new cotter pin, bending ends to secure.
   ⚠If torque specification is reached before cotter pin hole aligns, tighten further to next slot. Never loosen to align cotter pin hole.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
10. 10

    Snug control arm mounting bolts
    With the ball joint connected, snug both the front and rear control arm mounting bolts using an 18mm socket. Tighten until snug but do NOT torque to final specification yet. These bolts must be torqued with vehicle weight on the wheels to prevent bushing bind.
    ⚠Final torque must be performed with vehicle at normal ride height. Torquing at full droop will cause premature bushing failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
11. 11

    Reinstall wheel and lower vehicle
    Install the wheel and hand-tighten all lug nuts in a star pattern. Carefully lower the vehicle until the tire just contacts the ground but the jack stands still support most of the weight. Remove the jack stands, then lower the vehicle completely so full weight is on the wheels.
12. 12

    Final torque control arm bolts
    With vehicle weight on wheels and vehicle at normal ride height, use an 18mm socket and torque wrench to torque both the front and rear control arm mounting bolts to final specification. Torque the rear bolt first, then the front bolt.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
13. 13

    Torque wheel lug nuts
    Using a torque wrench with appropriate socket, torque all wheel lug nuts to specification in a star pattern. Make two complete passes to ensure even torque distribution.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Always install a new cotter pin at the ball joint castle nut
2. Ensure control arm mounting bolts are torqued only when vehicle is at normal ride height with weight on wheels
3. Verify ball joint boot is not torn or damaged during installation
4. Double-check all fasteners are torqued to specification before test driving

Verification

• Start engine and turn steering wheel full left and full right while stationary to check for binding or unusual noises
• Test drive vehicle at low speed and verify no clunking or rattling from front suspension
• After test drive, recheck control arm mounting bolt torque with vehicle weight on wheels
• Verify no grease leaking from ball joint boot
• Schedule alignment check within 50 miles as control arm replacement affects camber and caster settings

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