This procedure removes and replaces the pitman arm on a 2016-2024 Hyundai Tucson with the 2.5L I4 engine and AWD, connecting the steering gear to the steering linkage.

Warnings

Tools required

Parts

• Pitman arm × 1 — Use OEM specification
• Pitman arm castle nut × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Turn steering wheel to center position and note exact position for reinstallation
4. Raise front of vehicle and support securely on jack stands at manufacturer-specified points
5. Remove driver-side front wheel for improved access
6. Spray pitman arm connection points with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Mark pitman arm orientation
   Use a paint marker or center punch to mark the exact rotational position of the pitman arm relative to the steering gear shaft. This ensures proper steering wheel alignment upon reassembly. Mark both the arm and the shaft with corresponding alignment marks.
2. 2

   Remove cotter pin and castle nut
   Locate the castle nut securing the pitman arm to the center link. Straighten and remove the cotter pin using pliers. Discard the old cotter pin. Use a 24mm socket to remove the castle nut from the ball stud. Keep the nut accessible as you may need to thread it back on partway during puller operation.
3. 3

   Separate pitman arm from center link
   Install the pitman arm puller onto the ball stud connection between the pitman arm and center link. Tighten the puller forcing screw while maintaining pressure on the joint. The taper connection will release with a pop. Do not strike the joint with a hammer as this can damage the ball stud threads and taper seat.
   ⚠Ensure the puller is properly seated and centered before applying pressure to prevent tool slippage and injury.
4. 4

   Remove pitman arm shaft nut
   Locate the large nut securing the pitman arm to the steering gear sector shaft. This nut is typically 27mm and very tight. Use a breaker bar and appropriate socket to remove the pitman arm nut from the sector shaft. Note the orientation of any washers.
   Torque spec

   Pitman Arm Nut185 Nm (136 lb-ft)
5. 5

   Remove pitman arm from sector shaft
   Install the pitman arm puller between the pitman arm and the steering gear housing. Position the puller jaws behind the pitman arm and the forcing screw against the end of the sector shaft. Tighten the forcing screw gradually and evenly. The pitman arm will release from the tapered sector shaft. If extremely stuck, apply moderate penetrating oil around the shaft and wait 15 minutes before continuing.
   ⚠Do not use excessive force or impact tools as this can damage the steering gear sector shaft threads and internal bearings.
6. 6

   Clean mounting surfaces
   Use a wire brush to clean the steering gear sector shaft taper and splines. Remove all rust, corrosion, and old thread locker. Inspect the sector shaft for damage, scoring, or wear. Clean the taper seat inside the new pitman arm. Ensure all surfaces are clean and dry before installation.
7. 7

   Install new pitman arm onto sector shaft
   Align the new pitman arm splines with the sector shaft, ensuring the alignment marks you made during removal are properly matched. Slide the pitman arm onto the sector shaft taper. The arm should slide on with moderate hand pressure for the first portion of engagement. Ensure proper orientation before proceeding.
8. 8

   Install and torque pitman arm nut
   Install the pitman arm nut (use new nut if specified by manufacturer) and any washers in their original orientation. Thread the nut onto the sector shaft by hand until snug. Using a calibrated torque wrench, tighten the pitman arm nut to specification. This critical fastener draws the pitman arm fully onto the tapered shaft.
   ⚠️This is a critical steering component. Incorrect torque can result in pitman arm separation and complete loss of steering control. Verify torque wrench calibration.
   Torque spec

   Pitman Arm Nut185 Nm (136 lb-ft)
9. 9

   Connect pitman arm to center link
   Position the pitman arm ball stud into the center link taper hole. Ensure the taper seats are clean and free of debris. Install the castle nut and tighten by hand until seated. Using a torque wrench with appropriate socket, tighten the castle nut to specification.
   Torque spec

   Tie Rod Nut54 Nm (40 lb-ft)
10. 10

    Install cotter pin
    Install a new cotter pin through the castle nut and ball stud. If the castle nut slots do not align with the ball stud hole, tighten the nut slightly (not more than 1/6 turn) until alignment is achieved. Never loosen the nut to align. Bend the cotter pin ends to secure properly.
11. 11

    Reinstall wheel and lower vehicle
    Reinstall the driver-side front wheel, threading lug nuts by hand to prevent cross-threading. Snug lug nuts in a star pattern with a hand wrench. Lower the vehicle until the tire just contacts the ground. Torque the 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. Verify steering wheel is still centered with wheels pointing straight ahead
2. Check that all fasteners have been properly torqued using calibrated tools
3. Inspect all connections for proper engagement and cotter pin installation
4. Remove wheel chocks

Verification

• Start the engine and turn the steering wheel lock-to-lock while stationary to verify no binding or unusual noises
• Perform a slow-speed test drive in a safe area, checking for proper steering response and centering
• Verify steering wheel returns to center after turns without pulling to either side
• Check for any play or looseness in the steering by gently rocking the wheel back and forth
• Schedule a professional wheel alignment as pitman arm replacement affects toe adjustment and steering geometry

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