This procedure covers the removal and replacement of the rear lower control arm on a 2016-2024 Hyundai Tucson with the 2.5L I4 AWD engine.

Warnings

Tools required

Parts

• Rear lower control arm × 1 — Use OEM specification
• Ball joint nut (if not included with control arm) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock front wheels securely
3. Loosen rear wheel lug nuts while vehicle is on ground (do not remove)
4. Raise rear of vehicle using floor jack at designated rear jacking point
5. Support vehicle on jack stands placed at manufacturer frame jacking points
6. Remove rear wheel completely
7. Spray all control arm fasteners with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Support the rear knuckle assembly
   Place a floor jack under the rear knuckle/hub assembly with a block of wood between jack and knuckle. Raise jack slightly to take load off the control arm but do not lift vehicle. This prevents the knuckle from dropping when the control arm is disconnected.
2. 2

   Remove the ball joint nut
   Locate the ball joint connection at the outer end of the lower control arm where it connects to the knuckle. Remove the cotter pin if present. Using a 19mm socket, remove the ball joint nut completely. Keep the nut if it is in good condition; replace if damaged or excessively corroded.
   Torque spec

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

   Separate the ball joint from knuckle
   Using a ball joint separator tool or pickle fork, carefully separate the lower control arm ball joint from the knuckle. Position the tool between the control arm and knuckle, then apply force to break the taper fit. Tap with a hammer if necessary. The ball joint should pop free from the knuckle taper.
   ⚠Avoid damaging the ball joint boot if you plan to reuse the control arm. Use appropriate separator tool rather than excessive force.
4. 4

   Remove the front control arm mounting bolt
   Locate the front mounting bolt that connects the control arm to the front subframe or mounting bracket. This is typically a large bolt with a bushing. Using a 19mm socket and breaker bar, remove the bolt completely. Note the orientation of any washers or spacers for reinstallation.
   Torque spec

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

   Remove the rear control arm mounting bolt
   Locate the rear mounting bolt that connects the control arm to the rear subframe or mounting bracket. Using a 19mm socket and breaker bar, remove this bolt completely. Note the orientation of any washers or spacers. The control arm should now be free to remove.
   Torque spec

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

   Remove the lower control arm
   Carefully maneuver the control arm out of the vehicle. You may need to lower the floor jack supporting the knuckle slightly to create clearance. Inspect the mounting points on the subframe for damage, corrosion, or worn bushings.
7. 7

   Prepare and install new control arm
   Clean all mounting surfaces on the subframe with a wire brush. Compare the new control arm to the old one to verify correct part. Apply a thin coat of anti-seize to bolt threads (avoid getting on taper surfaces). Position the new control arm into place, aligning the mounting holes.
   ℹ️Do not fully tighten control arm mounting bolts at this stage. They must be torqued with vehicle weight on suspension.
8. 8

   Install control arm mounting bolts
   Insert both front and rear control arm mounting bolts through the bushings and subframe brackets. Thread the bolts by hand first to ensure proper alignment. Using a wrench, snug the bolts but do NOT torque to specification yet. Bolts should be tight enough to hold the arm in place but still allow slight movement.
9. 9

   Connect ball joint to knuckle
   Raise the floor jack under the knuckle to align the ball joint stud with the hole in the knuckle. The taper should seat fully into the knuckle taper bore. You may need to use a pry bar to align the holes. Ensure the ball joint seats completely before installing the nut.
10. 10

    Install and torque ball joint nut
    Thread the ball joint nut onto the stud by hand. Using a torque wrench and 19mm socket, torque the ball joint nut to specification. Install a new cotter pin if applicable and bend tabs to lock. Verify the ball joint is fully seated in the knuckle taper.
    Torque spec

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

    Reinstall wheel and lower vehicle
    Reinstall the rear wheel onto the hub. Thread all lug nuts by hand, then snug them in a star pattern with the wrench (do not torque yet). Remove the floor jack from under the knuckle. Carefully raise the vehicle slightly and remove the jack stands. Lower the vehicle completely so full weight is on the suspension.
12. 12

    Torque control arm bolts with weight on suspension
    With the vehicle on the ground and full weight on the rear suspension, crawl under the vehicle and torque both the front and rear control arm mounting bolts to specification using a torque wrench. This is critical for proper bushing alignment and longevity.
    ⚠Ensure vehicle is stable and securely on the ground. Use wheel chocks and engage parking brake before working under vehicle.
    Torque spec

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

    Torque wheel lug nuts
    Using a torque wrench and 21mm socket, torque all wheel lug nuts to specification in a star pattern. Make two complete passes to ensure even seating and proper torque.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Reassembly is covered in the main procedure steps
2. Ensure all fasteners are torqued to specification
3. Verify ball joint nut has cotter pin installed if applicable

Verification

• Test drive vehicle at low speed and verify no unusual noises or handling issues from rear suspension
• Check for any clunking or knocking sounds when going over bumps
• Verify steering tracks straight and vehicle does not pull to one side
• Schedule a professional wheel alignment within 100 miles of repair, as control arm replacement affects rear suspension geometry
• Re-check all torque specifications after 50-100 miles of driving

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