This procedure covers removal and installation of the front lower control arm (radius arm) on a 2016-2024 Hyundai Tucson with the 2.5L I4 AWD engine.

Warnings

Tools required

Parts

• Front lower control arm (radius arm) × 1 — Use OEM specification for left or right side
• Ball joint castle nut × 1 — Replace if cotter pin holes are damaged
• Control arm bushing bolts × 2 — Inspect and replace if damaged

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is on ground
4. Raise front of vehicle and support securely on jack stands at manufacturer lift points
5. Remove front wheel on side being serviced
6. Spray control arm bolts and ball joint nut with penetrating oil and let soak for 10-15 minutes

Procedure

1. 1

   Remove ball joint castle nut
   Remove the cotter pin from the ball joint castle nut. Using a 19mm socket, remove the castle nut securing the lower ball joint to the steering knuckle. Do not reuse the cotter pin.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
2. 2

   Separate ball joint from knuckle
   Insert ball joint separator tool between the lower control arm and steering knuckle. Apply pressure to separate the ball joint taper from the knuckle. Once separated, support the knuckle assembly to prevent stress on the CV axle and brake lines.
   ⚠Do not strike the steering knuckle or ball joint stud with a hammer as this can damage components.
3. 3

   Support lower control arm
   Position a floor jack under the lower control arm to support it during removal. Apply slight upward pressure to take load off the mounting bolts but do not compress the suspension significantly.
4. 4

   Remove front control arm mounting bolt
   Locate the front control arm mounting bolt at the subframe. Using a 22mm socket and breaker bar, remove the bolt completely. Note the position of any washers or spacers for reinstallation.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
5. 5

   Remove rear control arm mounting bolt
   Locate the rear control arm mounting bolt at the subframe. Using a 22mm socket and breaker bar, remove this bolt completely. The control arm should now be free to remove.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
6. 6

   Remove control arm from vehicle
   Lower the floor jack slowly and guide the control arm down and out from the subframe. Maneuver the arm past the CV axle and other components as needed. Inspect the removed arm for worn bushings, cracks, or damage.
7. 7

   Prepare replacement control arm
   Clean the mounting areas on the subframe with a wire brush. Compare the new control arm to the old one to ensure correct part. Check that bushings are properly seated and ball joint boot is intact and not torn.
8. 8

   Install new control arm
   Position the new control arm into the subframe mounting points. Align the ball joint stud with the hole in the steering knuckle. You may need to use a pry bar or jack to align holes properly. Insert both front and rear mounting bolts hand-tight only at this stage.
9. 9

   Install ball joint nut
   Thread the castle nut onto the ball joint stud by hand, ensuring it threads smoothly. Tighten to specification using a torque wrench. Align the castle nut slots with the cotter pin hole and install a new cotter pin. Bend cotter pin ends to secure.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
10. 10

    Reinstall wheel and lower vehicle
    Install the wheel and thread lug nuts by hand. Lower the vehicle until the tire just contacts the ground but vehicle weight is still primarily on jack stands. Torque lug nuts in a star pattern to specification. Then fully lower vehicle to ground.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
11. 11

    Final torque control arm bolts
    With vehicle weight fully on the suspension and wheels, torque both the front and rear control arm mounting bolts to specification. This is critical - torquing with suspension unloaded will cause premature bushing failure. Torque in sequence: front bolt first, then rear bolt.
    ⚠Control arm bolts MUST be torqued with vehicle at ride height. Failure to do so will twist bushings and cause premature wear.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification with vehicle at proper ride height
2. Verify cotter pin is properly installed and bent on ball joint castle nut
3. Check that no tools or parts were left in wheel well area

Verification

• Test drive vehicle at low speed and verify no unusual noises from front suspension
• Check for proper steering response and verify vehicle tracks straight
• Perform visual inspection of control arm installation to confirm proper seating
• Schedule front end alignment immediately after control arm replacement to prevent uneven tire wear

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