This procedure covers the replacement of the steering rack and pinion boots on a 2016-2024 Hyundai Tucson with a 2.5L I4 AWD engine, preventing contamination and preserving the steering rack assembly.

Warnings

Tools required

Parts

• Rack and pinion boot kit (left) × 1 — Use OEM specification
• Rack and pinion boot kit (right) × 1 — Use OEM specification
• Cotter pins (2mm or per specification) × 2 — Per tie rod end specification
• Rack and pinion boot clamps × 4 — Usually included in boot kit

Preparation

1. Park vehicle on level surface and engage parking brake
2. Center the steering wheel and lock it in place using a steering wheel lock or seatbelt through the wheel
3. Loosen front wheel lug nuts while vehicle is on the ground
4. Raise front of vehicle and support securely on jack stands at manufacturer-approved jacking points
5. Remove both front wheels completely
6. Spray tie rod end castle nuts and rack boot clamps with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Remove tie rod end cotter pins and castle nuts
   Remove the cotter pins from both tie rod end castle nuts using a cotter pin removal tool or pliers. Loosen and remove the castle nuts from the tie rod ends at the steering knuckles. Do not reuse the cotter pins.
   Torque spec

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

   Separate tie rod ends from steering knuckles
   Using a tie rod end puller or pickle fork, separate both tie rod ends from the steering knuckles. Apply steady pressure with the puller tool and strike the knuckle boss area with a hammer if necessary to break the taper free. Avoid damaging the tie rod end threads or steering knuckle.
   ⚠If reusing tie rod ends, avoid using a pickle fork as it can damage the boots; use a proper tie rod end puller instead
3. 3

   Remove outer boot clamps
   Locate the outer boot clamps (closest to the tie rod ends) on both sides of the steering rack. Using boot clamp pliers or cutting the clamps carefully, remove and discard the outer clamps from both boots. Note the orientation of the clamps for reinstallation.
4. 4

   Remove inner boot clamps
   Access the inner boot clamps (closest to the center of the rack). These may be located underneath the rack assembly. Remove and discard the inner clamps from both boots using boot clamp pliers or by carefully cutting them. Support the boot while removing clamps to prevent damage to the rack housing.
5. 5

   Remove old boots from rack
   Slide both old boots off the rack assembly toward the tie rod end side. Clean any old grease from the exposed rack gear teeth and housing using shop rags and brake cleaner. Inspect the rack surface for scoring, pitting, or damage. If significant damage is present, the entire rack assembly may need replacement.
   ⚠Inspect rack teeth carefully for wear or damage; torn boots often allow contaminants that damage the rack surface
6. 6

   Clean and inspect rack assembly
   Thoroughly clean the rack housing, tie rod connection points, and all mounting surfaces with brake cleaner and a wire brush. Remove all old grease, dirt, and debris. Inspect the rack housing breather valve (if equipped) and ensure it is not clogged. Check tie rod sockets for excessive play or wear.
7. 7

   Apply grease to rack assembly
   Apply a liberal amount of lithium or synthetic grease to the exposed rack gear teeth and the area where the boot will seal. Distribute grease evenly along the rack travel area. Most boot kits include the appropriate amount of grease; use all grease provided in the kit.
8. 8

   Install new boots onto rack
   Slide the new boots onto the rack from the tie rod end side, positioning them properly on both the rack housing and the tie rod connection area. Ensure the boots are not twisted and are seated properly in the grooves on both the inner (rack housing) and outer (tie rod) mounting surfaces. The bellows of the boot should have even folds without being stretched or compressed excessively.
9. 9

   Install inner boot clamps
   Install the new inner boot clamps on the rack housing side of both boots. Position the clamps in the groove provided on the boot and tighten securely using boot clamp pliers. Ensure the boot is not twisted and remains properly seated in the housing groove before fully tightening the clamp. The clamp should compress the boot firmly without cutting into the rubber.
10. 10

    Install outer boot clamps
    Install the new outer boot clamps on the tie rod end side of both boots. Ensure the boots are properly seated in the tie rod connection groove and not twisted. Tighten the outer clamps securely using boot clamp pliers, compressing the boot firmly to create a proper seal.
11. 11

    Verify boot installation and rack positioning
    Verify both boots are properly installed with no twists, tears, or improper seating. Check that all four clamps are tight and secure. Manually move the rack from lock to lock (if accessible) to ensure boots accordion properly without binding or excessive stretching. The boots should expand and contract smoothly through the full range of motion.
12. 12

    Reinstall tie rod ends to steering knuckles
    Clean the tie rod end tapers and steering knuckle bores with brake cleaner. Install both tie rod ends into the steering knuckles, ensuring the taper seats properly. Thread the castle nuts onto the tie rod studs and torque to specification. Align the castle nut slots with the tie rod end holes. If the slots do not align, tighten the nut further (never loosen) until the next slot aligns with the hole.
    Torque spec

    Tie Rod End Castle Nut55 Nm (41 lb-ft)
13. 13

    Install new cotter pins
    Insert new cotter pins through the tie rod end castle nuts and tie rod studs. Bend the cotter pin ends properly to secure the castle nuts. Ensure the cotter pins are fully seated and the ends are bent to prevent the pins from backing out.
14. 14

    Reinstall wheels and lower vehicle
    Reinstall both front wheels and hand-tighten the lug nuts in a star pattern. Lower the vehicle until the tires just touch the ground. Torque the wheel 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. Ensure steering wheel lock or securing device is removed before test driving
2. Verify all boot clamps are tight and boots are properly seated with no leaks or damage
3. Confirm all tie rod end castle nuts are torqued and cotter pins are properly installed

Verification

• Turn the steering wheel lock to lock while stationary and verify smooth operation with no binding or unusual noises
• Inspect both rack boots for proper movement, ensuring they accordion smoothly without excessive stretching or compression
• Test drive the vehicle at low speed and verify proper steering feel and response
• Re-inspect all boot clamps and connections after test drive for any signs of movement or leakage
• Schedule a professional wheel alignment as tie rod ends were disconnected during this procedure

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