This procedure replaces the electric power steering rack on a 2016-2024 Hyundai Tucson with the 2.5L I4 AWD engine, including removal of tie rods, subframe access, and steering column disconnection.

Warnings

Tools required

Parts

• Power steering rack assembly × 1 — Use OEM specification
• Tie rod end cotter pins × 2 — Use OEM specification
• Steering rack O-rings (if applicable) × 2 — Use OEM specification
• Lower intermediate steering shaft bolt × 1 — Use OEM specification - may be torque-to-yield

Preparation

1. Park vehicle on level ground and set parking brake
2. Disconnect negative battery terminal and wait 3 minutes minimum for airbag system discharge
3. Turn steering wheel to center position (wheels straight ahead)
4. Lock steering wheel in place using steering wheel lock or secure to seat with bungee cord
5. Raise front of vehicle and support securely on jack stands at manufacturer lift points
6. Remove both front wheels
7. Mark tie rod position on inner tie rod threads with paint or marker for reference

Procedure

1. 1

   Remove tie rod ends
   Remove cotter pins from tie rod end castle nuts using cotter pin puller. Loosen but do not fully remove the castle nuts. Use tie rod separator tool to break tie rod ends free from steering knuckles. Remove castle nuts and separate tie rod ends completely. Count and record turns required to remove outer tie rod ends from inner tie rods for approximate reassembly reference.
   Torque spec

   Tie Rod End Castle Nut55 Nm (41 lb-ft)
2. 2

   Disconnect intermediate steering shaft
   Working from inside the vehicle under the dash, locate the lower intermediate steering shaft connection to the steering column. Mark the relationship between the shaft and steering gear input shaft with paint or punch marks. Remove the lower pinch bolt connecting the intermediate shaft to the steering rack input shaft. Carefully slide the shaft upward to separate from the rack splines. Verify steering wheel remains locked in center position.
3. 3

   Disconnect electrical connectors
   Locate the electric power steering motor connector on the steering rack assembly. Press the locking tab and disconnect the electrical connector. On AWD models, you may need to disconnect additional sensors. Secure connectors away from work area to prevent damage.
4. 4

   Remove heat shields and guards
   Remove any heat shields or splash guards that obstruct access to the steering rack mounting bolts. These are typically secured with 10mm bolts. Set aside hardware for reinstallation.
5. 5

   Support subframe (if required)
   Depending on model year, you may need to slightly lower the front subframe for rack removal clearance. Place a transmission jack or jack stand under the subframe center. Remove or loosen front subframe mounting bolts as required (typically 2-4 bolts), then lower subframe approximately 50mm. Do not fully remove subframe. Consult service manual for your specific year if uncertain.
   ⚠Support subframe securely before loosening mounting bolts. Allow only enough drop for rack removal clearance.
6. 6

   Remove steering rack mounting bolts
   Locate the two steering rack mounting bolts that secure the rack to the subframe or crossmember. These are typically accessed from underneath the vehicle. Remove both rack mounting bolts completely. Note the location and orientation of any spacers or shims.
   Torque spec

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

   Remove steering rack assembly
   With mounting bolts removed, carefully maneuver the steering rack assembly out through the driver side wheel well. You may need to rotate and tilt the assembly to clear the subframe and suspension components. Have an assistant support the rack as it can be heavy and awkward. Once clear, lower rack from vehicle and place on clean work surface.
8. 8

   Transfer components to new rack
   If inner tie rods are not included with new rack, carefully transfer them from old rack to new rack. Use two wrenches to prevent twisting the rack housing. Apply thread locker to inner tie rod threads per manufacturer specifications. Ensure tie rod jam nuts are transferred. Install any brackets, heat shields, or sensors from old rack to new rack in identical positions.
   ⚠Hold rack housing securely when tightening inner tie rods to prevent internal damage.
   Torque spec

   Tie Rod Nut54 Nm (40 lb-ft)
9. 9

   Install new steering rack
   Maneuver new steering rack assembly into position through the driver side wheel well, reversing the removal path. Align rack mounting holes with subframe mounting points. Install both rack mounting bolts finger-tight initially. Ensure rack is properly seated and centered before final tightening. Torque rack mounting bolts to specification in the sequence recommended in service manual.
   ℹ️Verify rack is centered with equal tie rod travel to each side before tightening mounting bolts.
   Torque spec

   Rack Bolts102 Nm (75 lb-ft)
10. 10

    Reconnect intermediate steering shaft
    Ensure steering wheel is still locked in center position and rack input shaft is centered. Align marks made during disassembly and slide intermediate shaft onto rack input shaft splines. Install new pinch bolt (if torque-to-yield type) and torque to specification. Verify shaft connection is secure with no play.
11. 11

    Raise subframe (if lowered)
    If subframe was lowered, carefully raise it back to original position using the jack. Align all mounting bolt holes and install subframe bolts. Torque subframe bolts to specification per service manual. Remove support jack.
12. 12

    Connect electrical connectors
    Reconnect the electric power steering motor connector to the rack assembly. Ensure connector locks fully into place with an audible click. Reconnect any additional sensors that were disconnected.
13. 13

    Install tie rod ends
    Thread outer tie rod ends onto inner tie rods the same number of turns recorded during removal to approximate previous toe setting. Insert tie rod end studs into steering knuckle tapers. Install castle nuts and torque to specification. Install new cotter pins through castle nut slots. If cotter pin hole does not align, tighten nut slightly until next slot aligns (never loosen). Bend cotter pin ends to secure.
    ⚠Never loosen castle nut to align cotter pin hole. Only tighten to next alignment point.
    Torque spec

    Tie Rod End Castle Nut55 Nm (41 lb-ft)
14. 14

    Reinstall wheels and lower vehicle
    Reinstall heat shields and splash guards removed earlier. Install both front wheels and hand-tighten lug nuts in star pattern. Lower vehicle to ground. Torque wheel lug nuts to specification in star pattern.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Reconnect negative battery terminal
2. Start engine and verify electric power steering system initializes without fault codes
3. Turn steering wheel lock to lock slowly while stationary to verify full operation and no binding
4. Check for any unusual noises or vibrations from steering system

Verification

• Start engine and verify power steering assist is functioning normally
• Turn steering wheel slowly from lock to lock and verify smooth operation with no binding, clicking, or unusual noises
• Verify steering wheel returns to center properly when released
• Check for any warning lights related to power steering on instrument cluster
• Test drive vehicle at low speed in safe area to verify steering response
• Schedule immediate professional wheel alignment as toe settings will be affected by rack replacement
• After alignment, verify steering wheel is centered when driving straight

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