This procedure covers the replacement of worn radius arm (lower control arm) bushings on the 2016-2024 Hyundai Tucson 2.5L AWD, requiring removal of the lower control arm assembly.

Warnings

Tools required

Parts

• Lower control arm bushings (front and rear) × 2 — Use OEM specification
• Ball joint castle nut (if damaged) × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen wheel lug nuts while vehicle is on ground
3. Raise front of vehicle and support securely on jack stands at manufacturer-specified jacking points
4. Remove front wheel on side being serviced
5. Spray all control arm bolts and ball joint nut with penetrating oil and allow to soak for 10-15 minutes
6. Clean area around control arm mounting points with wire brush to expose markings and prevent contamination

Procedure

1. 1

   Remove ball joint castle nut
   Remove the cotter pin from the ball joint castle nut. Using a 21mm socket, remove the castle nut securing the lower ball joint to the steering knuckle. Do not reuse the cotter pin.
2. 2

   Separate ball joint from knuckle
   Using a ball joint separator tool or pickle fork, separate the lower ball joint taper from the steering knuckle. Position the tool between the control arm and knuckle, then strike or tighten to break the taper seal. The knuckle will drop when separated.
   ⚠Support the knuckle and brake assembly to prevent strain on brake hose and ABS sensor wiring once ball joint separates.
3. 3

   Remove rear control arm mounting bolt
   Locate the rear control arm mounting bolt that passes through the rear radius arm bushing. Using a 19mm socket and wrench, remove the bolt and washer securing the rear of the control arm to the subframe. Support the control arm with your hand as you remove the bolt.
4. 4

   Remove front control arm mounting bolt
   Using a 19mm socket and wrench, remove the front control arm mounting bolt that passes through the front radius arm bushing. The control arm is now free and can be removed from the vehicle. Note the orientation and position of any washers or spacers.
5. 5

   Inspect control arm and prepare for bushing removal
   Inspect the control arm for cracks, bends, or damage. Check the ball joint for excessive play or torn boots. Clean the bushing bores in the control arm thoroughly with a wire brush. Mark the orientation of existing bushings before removal if they have offset positioning.
6. 6

   Press out old bushings
   Using a hydraulic press or control arm bushing tool, press out the old bushings from both the front and rear positions of the control arm. Apply pressure evenly and ensure the control arm is properly supported. The bushing outer shell should press out of the arm bore. If using a bushing tool, follow manufacturer instructions for your specific tool set.
   ⚠Ensure press tools are properly aligned to avoid damaging the control arm bore. Bushings may require significant force to remove.
7. 7

   Clean bushing bores
   Clean all old rubber residue and debris from the control arm bushing bores using a wire brush and clean cloth. Inspect bores for scoring or damage. Apply a light coat of soapy water or bushing installation lubricant to the bores to ease installation of new bushings.
8. 8

   Press in new bushings
   Position the new bushings in their respective bores, ensuring proper orientation if bushings are directional. Using the hydraulic press or bushing tool, press the new bushings into the control arm until they are fully seated and flush with the arm. The bushing outer shell should be pressed in evenly without cocking or binding.
   ⚠Verify bushing orientation before pressing. Some bushings have offset centers and must be installed in the correct direction per service manual diagrams.
9. 9

   Install control arm front mounting
   Position the control arm into the subframe mounting point and loosely install the front mounting bolt with washer. Thread the bolt by hand first to ensure proper alignment. Do not tighten at this time - leave the bolt loose enough for the control arm to pivot.
10. 10

    Install control arm rear mounting
    Align the rear of the control arm with its subframe mounting point. You may need to use a pry bar to align the holes. Loosely install the rear mounting bolt with washer. Thread by hand first. Do not tighten - both control arm bolts must remain loose until vehicle weight is on suspension.
11. 11

    Connect ball joint to knuckle
    Lift the steering knuckle and align the ball joint stud with the knuckle taper. You may need to use a floor jack under the lower control arm to raise it to the correct height. Install the castle nut and tighten to specification. Align the castle nut slots with the ball joint stud hole and install a new cotter pin. Bend cotter pin ends to secure.
    Torque spec

    Ball Joint Nut88 Nm (65 lb-ft)
12. 12

    Reinstall wheel and lower vehicle
    Reinstall the wheel and hand-tighten the lug nuts in a star pattern. Lower the vehicle until the tire just touches the ground but the suspension is not yet compressed. Torque the wheel lug nuts to specification in a star pattern. Then lower the vehicle completely so full weight is on the suspension.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
13. 13

    Torque control arm mounting bolts
    With the vehicle at normal ride height and full weight on the suspension, torque both the front and rear control arm mounting bolts to specification. This is critical - torquing the bolts while suspension is hanging will cause premature bushing failure. Torque each bolt while the vehicle is on the ground.
    ⚠Control arm bolts MUST be torqued with vehicle weight on suspension. Failure to do so will twist the bushings internally and cause premature failure within a few thousand miles.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Install wheel and torque lug nuts to specification in a star pattern
2. Verify all fasteners are properly torqued
3. Ensure cotter pin is properly installed and bent on ball joint castle nut

Verification

• Test drive vehicle at low speed and verify no clunking or unusual noises from front suspension
• Perform steering wheel lock-to-lock test while stationary to verify ball joint movement is smooth
• Visually inspect control arm mounting bolts to ensure they are tight and not backing out
• Schedule a professional wheel alignment within 50 miles of completing this repair, as suspension geometry has been altered

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