This procedure covers the removal and replacement of the steering gear box (rack and pinion assembly) on a 2016-2024 Hyundai Tucson with 2.5L I4 AWD engine and electric power steering.

Warnings

Tools required

Parts

• Steering gear box assembly × 1 — Use OEM specification
• Steering column universal joint coupling (if damaged) × 1 — Use OEM specification
• Cotter pins for tie rod ends × 2 — Use OEM specification
• Subframe mounting bolts (if reuse not recommended) × 4 — Use OEM specification

Preparation

1. Park vehicle on level ground and set parking brake
2. Disconnect negative battery cable and wait 3 minutes for airbag system discharge
3. Turn steering wheel to center position and lock in place using steering wheel lock or remove ignition key
4. Raise vehicle and support securely on jack stands at manufacturer-specified lift points
5. Remove front wheels using 21mm socket
6. Mark alignment position of steering column universal joint to gear input shaft with center punch or paint
7. Place drain pan under work area to catch any residual moisture or debris

Procedure

1. 1

   Remove front wheels and access components
   With vehicle raised and supported, remove both front wheels. Remove the engine lower splash shield and any under-body panels that restrict access to the steering gear and front subframe area. This typically includes multiple plastic clips and fasteners.
2. 2

   Disconnect outer tie rod ends
   Remove the cotter pins from both outer tie rod end castle nuts. Using a 19mm socket, loosen the tie rod end castle nuts but do not remove completely. Use a ball joint separator or tie rod end puller to separate the tie rod ends from the steering knuckles. Once separated, remove the castle nuts completely and set tie rod ends aside. Mark the position of tie rod adjustment if reusing the tie rods.
   ⚠Do not strike the steering knuckle or tie rod with excessive force as this may damage the ball joint boot or steering components.
   Torque spec

   Tie Rod End Castle Nut55 Nm (41 lb-ft)
3. 3

   Disconnect steering column from gear box
   Working from inside the vehicle or from underneath (depending on access), locate the steering column universal joint coupling at the steering gear input shaft. Remove the pinch bolt securing the universal joint to the gear input shaft using appropriate socket. Carefully separate the universal joint from the gear input shaft by pulling upward on the steering column while prying gently if needed. Verify alignment marks are visible for reassembly.
   ⚠️Ensure steering wheel remains locked in center position throughout this procedure to prevent clock spring damage.
4. 4

   Remove heat shields and brackets
   Remove any heat shields, wiring harness brackets, or other components mounted to or near the steering gear box. On AWD models, carefully inspect for clearance around the front differential and transfer case components. Remove the exhaust heat shield if it restricts access to the steering gear mounting bolts.
5. 5

   Support front subframe
   Position a transmission jack or suitable subframe support jack under the front subframe. The subframe may need to be lowered slightly to access the steering gear box mounting bolts. Support the subframe securely but do not apply lifting pressure yet.
   ⚠Ensure jack is stable and positioned to prevent subframe from shifting during bolt removal.
6. 6

   Remove steering gear mounting brackets and bolts
   Locate the steering gear mounting bolts that secure the rack to the front subframe or crossmember. There are typically two main mounting brackets with bolts passing through rubber isolators. Remove these mounting brackets and bolts. Note the position and orientation of any washers, spacers, or isolator bushings for reassembly.
   ℹ️Support the steering gear by hand or with a strap as you remove the final mounting bolts to prevent it from falling.
   Torque spec

   Rack Bolts102 Nm (75 lb-ft)
7. 7

   Lower subframe if necessary
   If access is restricted, carefully remove the front subframe mounting bolts (typically 4 bolts). Lower the subframe 2-4 inches using the transmission jack to create clearance for steering gear removal. Do not lower excessively or disconnect other components unless absolutely necessary. On AWD models, verify clearance around front differential and axle shafts.
   ⚠Monitor brake lines, wiring harnesses, and AWD driveline components for tension as subframe is lowered. Do not exceed safe stretch limits.
8. 8

   Remove steering gear box from vehicle
   With mounting bolts removed and adequate clearance created, carefully maneuver the steering gear box assembly out through the driver side wheel well or downward through the subframe area (depending on vehicle configuration). The gear box may need to be rotated or tilted to clear the front differential housing on AWD models. Remove the assembly from the vehicle.
9. 9

   Transfer components to new gear box
   If the outer tie rods are being reused, transfer them to the new steering gear box. Count and record the number of threads visible on the inner tie rod before removal to maintain approximate toe setting. Clean all mounting points on the subframe and crossmember with a wire brush. Inspect universal joint coupling for wear or damage and replace if necessary.
10. 10

    Install new steering gear box
    Position the new steering gear box assembly into the vehicle using the reverse path of removal. Align the gear box into the mounting brackets on the subframe. If subframe was lowered, ensure the gear box is positioned correctly before raising the subframe back into place. Install mounting bracket bolts finger-tight initially.
11. 11

    Raise and secure subframe
    If the subframe was lowered, carefully raise it back to the original position using the transmission jack. Align all subframe mounting holes and install subframe mounting bolts. Torque subframe bolts to manufacturer specification (consult service manual). Once subframe is secured, torque the steering gear mounting bolts to specification.
    ℹ️Verify subframe is fully seated against body mounts before final torquing to prevent misalignment.
    Torque spec

    Rack Bolts102 Nm (75 lb-ft)
12. 12

    Connect steering column to gear box
    Align the steering column universal joint coupling with the steering gear input shaft, matching the alignment marks made during disassembly. Ensure the steering wheel is still locked in the centered position. Install the universal joint pinch bolt and torque to manufacturer specification (consult service manual for this specific torque value).
    ⚠️Verify steering wheel is centered and locked before connecting universal joint to prevent clock spring damage.
13. 13

    Reinstall heat shields and brackets
    Reinstall all heat shields, exhaust shields, wiring harness brackets, and protective covers that were removed for access. Ensure no wiring or hoses are pinched or in contact with hot exhaust components.
14. 14

    Reconnect outer tie rod ends
    Install the outer tie rod ends into the steering knuckles on both sides. Install the castle nuts and torque to specification. Install new cotter pins through the castle nut slots, bending the pins to secure. Verify tie rod ends are fully seated in the knuckle tapers.
    ℹ️Always use new cotter pins. Never reuse old cotter pins as they may fail.
    Torque spec

    Tie Rod End Castle Nut55 Nm (41 lb-ft)
15. 15

    Reinstall wheels and lower vehicle
    Reinstall the engine splash shields and under-body panels. Install both front wheels and hand-tighten lug nuts in a star pattern. Lower the vehicle to the ground and torque wheel lug nuts to specification in a star pattern.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Reconnect negative battery cable
2. Start engine and verify no warning lights related to steering system are illuminated
3. Turn steering wheel lock-to-lock slowly while stationary to verify full range of motion without binding or unusual noise
4. Check for proper steering wheel centering with wheels pointed straight ahead

Verification

• Perform a test drive at low speed in a safe area to verify steering response and centering
• Listen for any unusual noises during steering operation (clunks, grinding, or binding)
• Verify steering wheel returns to center after turning
• Schedule a professional wheel alignment as toe and other settings will be affected by this repair
• Verify no warning lights remain on the instrument cluster related to steering or SRS systems
• Re-torque wheel lug nuts after 50-100 miles of driving

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